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CROSS-REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit under 35 U.S.C. §119 of Mexican Patent Application No. MX/a/2012/010896 filed Sep. 21, 2012, which is hereby incorporated by reference in its entirety. FIELD OF THE INVENTION [0002] The present invention relates to a microemulsion, its preparation and use for injection into oil reservoirs for enhancing recovery. The invention is directed to a procedure for the preparation of a microemulsion, which is formulated with a surfactant, co-surfactant and brine, in defined proportions. The procedure includes the steps of mixing, agitation, maturation and application, thus allowing the reduction of viscosity of heavy and extra-heavy oils, thus making its transport and handling easier. BACKGROUND [0003] It is estimated that at the end of a secondary oil recovery process, only about 30% to 40% of original oil reserve is recovered, while the rest of the crude oil is retained in the formation due to a competition process between capillary and viscosity forces. [0004] The recovery of the remaining 60% to 70% can be achieved by unconventional methods that generally are classified as Enhanced Oil Recovery, or EOR, which are used for obtaining any additional production by introducing artificially produced energy within the site. Thus, some processes within this category are water injection, high pressure gas and steam injection, as well as chemicals injection. Other EOR processes and their combinations involve the introduction of additional thermal energy. One of the most effective chemical processes is the injection of surfactants using micellar solutions for micro emulsions formation. [0005] Also, the dispersion of some chemical species are common in the oil recovery processes and they find a wide range of applications to modify the properties of heavy crude oils, thus making it lighter crudes in terms of viscosity and for reducing the level of contaminants like sulfur and metals, which improves the flow overall and makes it to flow easily to the surface. [0006] Micro emulsions are micellar solutions with the characteristics of surfactant type solutions. The degree of applicability will depend on the characteristics of the surfactant and its behavior with respect to some system variables. [0007] Previous works report some methods for micro emulsions preparation, for example European Patent 2 096 411 T3 describes the preparation of a microemulsion as a flavor enhancing agent that does not require any mixing stage for application in the food industry. Also, it favors microemulsion formation of other flavor enhancing mixtures of immiscible foods and triglyceride type oils, together with the interaction of a hydrophilic surface active agent. [0008] U.S. Pat. No. 4,146,499 discloses a method of dispersing an immiscible liquid in the aqueous phase to form a microemulsion. The method includes the stage of selecting a primary surfactant that is amphiphillic, together with a surface active agent that is used in a liquid that is water immiscible, which is dispersed in another liquid that is water immiscible. Thus, a surface active agent in the aqueous phase has to disperse the immiscible liquid, and a secondary surfactant in the aqueous phase is used, which has a HLB (Hydrophilic-Lypophilic-Balance) higher than the parent surfactant. [0009] U.S. Pat. No 4,557,734 discloses production of hybrid micro emulsions of fuel that are prepared from vegetable oil, such as seed of soybean oil, methanol or ethanol, a straight chain isomer of octanol, and optionally, water. It describes the production of fuels using 2-octanol, anhydrous methanol and soybean seed oil. Also, it proposes mixing triolein, different individual alkanols C 4 -C 14 and water, to provide a composition which is water tolerant. [0010] U.S. Pat. No. 5,045,337 describes some micro emulsions that are thermodynamically stable, transparent and uniform, which are prepared from a polar solvent, a monoester and a specific di-ester of polyglycerol and a lipid. The microemulsion of this patent contains 90% to 99.8% of a lipid material and approximately 0.1% to 5% of a polar solvent. The polar solvent can be selected from water, glycerol, propylene glycol and di-propylene glycol. [0011] European patent DE 2829617 C2, describes a microemulsion for use in oil recovery methods, especially useful under high salinity water conditions. These include a water mixture that contains an excess of monovalent and di-valent salts, a hydrocarbon, an amphoteric surfactant that contains nitrogen compounds and a co-surfactant agent comprising at least one alcohol with C 1 C 10 chain. [0012] Venezuelan Patent A042819 of October 1985 discloses a method for oil recovery, where a microemulsion with a superior phase or with intermediary phase and an immiscible aqueous phase are simultaneously injected into an underground formation. The viscosity of the injected phase is adjusted in such a way that the relationship between their viscosity and the one for the aqueous phase microemulsion viscosity approaches the brine/oil viscosity ratio of the site. [0013] U.S. Pat. No. 3,981,361 dated Sep. 21, 1976, describes a method for oil recovery from subterranean formations using a micro emulsion, where the surfactant added to the solution is a dodecyl-benzene-sulfonate of xylene monoethanolamine salt and the co-surfactant is a tertiary Amyl alcohol. SUMMARY OF THE INVENTION [0014] In contrast to prior technologies, the present invention involves the formation and application of a microemulsion formulated with amphiphilic molecules, i.e. having hydrophilic and lipophilic groups in the same molecule for modifying the interfacial tension of heavy hydrocarbons, together with co-surfactant and brine, in defined proportions. The formulation procedure comprises the mixing, agitation, maturation and application, thus affording the viscosity reduction heavy and extra-heavy oils, thus facilitating their transportation through pipelines [0015] The process of this invention involves the injection of heavy and extra-heavy crude oil with a displacement agent that is completely miscible in oil. The displacement agent is a microemulsion of a surfactant, a co-surfactant and brine. As a result, the interfacial tension of the crude oil is significantly reduced, while the capillary number tends to infinite values, which means that the predominant forces are not capillary forces (i.e., surface tension inside the pores), but surface forces (i.e., fluid viscosity). Thus, the displacement of oil from the pores in the rock is promoted by the microemulsion-containing displacement agent, which improves the oil mobility from the well. Under ideal conditions, the microemulsion displacing fluid is injected into the well where the microemulsion and oil are mixed in a transition zone in the well, then expand and move through the porous medium, which displaces the oil ahead of the microemulsion as if a piston pushed it. [0016] Thus, the displacement of oil is promoted inside the pores, which are cleared by the microemulsion displacement agent, thus promoting mobility of the oil. Under ideal conditions, the displacing fluid and oil are mixed in a mixing zone or transition zone in the pores of the rock. The microemulsion displacing fluid then expands and moves through the porous medium, which displaces the oil in the pores. BRIEF DESCRIPTION OF THE DRAWINGS [0017] FIG. 1 represents the residual oil trapped in the pores of rocks. [0018] FIG. 2 represents the capillaries and hydrodynamic forces acting on a drop of oil that is trapped in a pore of a rock. DETAILED DESCRIPTION OF THE INVENTION [0019] After primary recovery, residual oil remains in the pores of rocks at the site in the form of discontinuous cells, due to capillary action forces. FIG. 1 illustrates this crude. [0020] The petroleum remaining within the pores of rocks is in the form of globules that generate a hydrodynamic pressure gradient, which is discontinuous due to capillary forces. This phenomenon is the result of a competition process between viscous and capillary forces, as shown in FIG. 2 . [0021] The present invention relates to a process for the preparation and utilization of a micro-emulsion, which reduces the viscosity of heavy and extra-heavy petroleum oils, facilitating crude oil flow, and increases its mobility and eases its pipeline transport. Such results are achieved by injection of a microemulsion containing a surfactant, which reduces the interfacial tension between oil and water, to an approximate value of 0.001 dynes/cm. The low interfacial tension is needed to overcome the capillary forces that trap the oil, and makes it possible to improve the crude oil mobility. The surfactants are injected in the form of micellar solutions or microemulsions, in order to take advantage of the low Interfacial tension produced in the formation, thus improving the efficiency of the oil displacement. [0022] The invention is also directed to the secondary recovery of heavy crude oil having °API of 10-12, preferably °API of 10.5-12, by injecting the microemulsion into the well to form a crude oil emulsion in the pores. The formation of the crude oil emulsion forces the crude oil from the pores. [0023] The microemulsion forms a stable phase, optically clear, i.e., transparent or translucent, with low viscosity and containing a surfactant, and a co-surfactant, such as an alcohol, and brine. The microemulsion is highly miscible in hydrocarbons and forms a homogeneous phase with the hydrocarbon to form an emulsion of the brine and hydrocarbon crude oil at the interface between the microemulsion and the crude oil in the pores. Preparation of the Microemulsion [0024] The microemulsion preparation includes two stages. The first one is a mixture of the surfactant and the co-surfactant, such as a primary alcohol. Suitable surfactants include , nonyl phenol ethoxylate, sodium dodecyl-benzene-sulfonate, alkylsulfonate of alkylamine, alkylsulfonate of polyalkylamines, alkanolamides, alkanolamines, glycolesters, monoester of ethyleneglycol, polyoxyethylene alcohols, polyoxyethylene alkylamines, polyxyethylene alkylamides, polyglycerol esters, polyoxyalkylene polyol-esters, sodium carboxymethylcelulose. [0025] A co-surfactant is needed to form a more stable emulsion. This is achieved by the molecular packing properties of compounds, such as alcohols, including those having a medium-chain-length, amines, propylene glycol and alkanolamines. Preferable co-surfactants include primary alcohols, such as_methanol , ethanol , propan-1-ol, butan-1-ol , pentan-1-ol , hexan-1-ol , heptan-1-ol , octan-1-ol, nonan-1-ol , decan-1-ol, undecan-1-ol, dodecan-1-ol , tridecan-1-ol , tetradecan-1-ol , pentadecan-1-ol. Preferred primary alcohols, include butanol, and the medium-chain-length alcohols. [0026] Usually, a specific surfactant/co-surfactant ratio is needed. Specific functions of the co-surfactants are: Interfacial tension reduction, fluidity increase in the interfacial film (Ds), a decrease of repulsive interactions between charged head groups, partition between two phases (improved mutual solubility). [0027] The ratio of surfactant to primary alcohol may be, for example, a weight ratio of 10/1 to 1.2/1, preferably between 7/2 and 4/3. [0028] Suitable amounts of surfactant in the mixture based on the total weight of the mixture are between 45 and 80 wt. %, preferably between 65 and 70 wt. % based on the total weight of the surfactant and cosurfactant. Suitable amounts of primary alcohol in the mixture are between 10 and 30 wt. %, preferably between 15 and 25 wt. % based on the total weight of the surfactant and cosurfactant. [0029] Suitable mixing temperatures are between 15° C. and 80° C., preferably between 25° C. and 40° C. The mixture is agitated for 5-90 min, preferably 10-50 min, using an agitation or stirring speed of 200 to 800 rpm until formation of a clear solution. In a second stage, an amount of brine is added with a concentration of 1,000-10,0000 ppm salt, such as NaCl, preferably in the interval 50000-80000 ppm salt, with 70,000 ppm salt being especially preferred, for obtaining a ratio between water and surface active agent of 1:1, preferably 1: 0.4. The agitation continues by stirring at a speed of 100-1000 rpm, preferably 200-800 rpm, for 5-90 min, preferably for 20-50 min, to obtain a clear or perfectly clear solution. Once the solution is crystal clear, it is transferred to a covered container, such as a jar with a lid, where it remains at rest, in a cool place, i.e., at 15-35° C. for 0.5 to 6 h, preferably 1 to 3 h. The container is covered only to avoid dust or airborne contaminants. [0030] The injection of the microemulsion to a well containing heavy oils, which is covered in the present invention, is characterized by its dispersed state at the molecular level and in this form, its interaction with asphaltenic molecules is promoted, thus affording a mobility improvement of the heavy crude oil. The microemulsion is used at the concentration range from 5,000 to 50,000 ppm wt. based on the heavy oil phase, preferably from 5,000 to about 10,000 ppm wt., corresponding to from 0.5 to about 1 wt. % based on the weight of the crude oil. The microemulsion is highly miscible in hydrocarbons and integrates in a homogeneous phase. EXAMPLES [0031] The following are examples of the microemulsion, its preparation and implementation, without limiting the scope of the present invention. Example 1 [0032] A heavy crude from southeast region of Campeche, Mexico, was used for the tests. This oil presents some properties as reported in Table 1. [0033] A microemulsion was prepared as described above: [0034] The experiments were performed in a reactor batch with a capacity of 500 ml, containing 200 g of 10 ° API oil and 1 g of microemulsion prepared with the following formulation: 60 wt. % of surfactant(nonyl-phenol ethoxylate), 25 wt. % butyl alcohol and 15% by weight of brine with a concentration of 70,000 ppm weight of anhydrous sodium chloride. The reactor was closed and the ingredients were homogeneously mixed at 300 rpm for 20 minutes at a temperature of 25° C., under atmospheric pressure. The product was subsequently recovered and its viscosity is measured. It is noted that the decline in viscosity is remarkable, namely, from 9720 to 7012 cSt (Example 1), measured at 37.8 ° C. Table 1 shows loads and product viscosities in function of temperature for several crude oils having different API Gravity. [0000] TABLE 1 Properties Crude Example 1 Example 2 Example 3 Example 4 Example 5 Gravity (° API) 10.5 11.8 11.5 11.0 11.5 11.0 Viscosity 37.8° C. 9720 7012 6970 5628 5160 4503 (cSt) 54.4° C. 2442 1951 1830 1625 1586 1399 82.2° C. 331 321 311 297 252 228 98.9° C. 188 167 159 151 153 139 Example 2 [0035] In a reactor batch with a capacity of 500 ml, 200 g of 10 °API crude oil are placed, together with 1.5 g of a micro emulsion, which was prepared from 65 wt. % of surfactant (sodium dodecyl-benzene-sulfonate), 20 wt. % of methanol and 15% by weight of brine with a concentration of 70,000 ppm. After closing the reactor, homogenous mixing was performed at 300 rpm for 20 min, at a temperature of 25° C. and atmospheric pressure. Subsequently, the product was recovered and its viscosity was determined. It is noted that there is a decline from 9720 to 5628 cSt, measured at 37.8 ° C., as reported in Table 1, which reports the product viscosities of several tests. Example 3 [0036] In a batch type reactor with a capacity of 500 ml, 200 g of a crude oil having 10 °API density were placed together with 1.5 g of a microemulsion which was prepared from 55 wt. % of surfactant (sodium dodecyl-benzene-sulfonate), 30 wt. % of methanol and 15% by weight of brine with a concentration of 70,000 ppm. After closing the reactor and homogeneously mixing the contents at 300 rpm for 20 min, at a temperature of 25° C. and atmospheric pressure, the crude oil is recovered and its viscosity is determined. The viscosity of the crude oil was found to decline from 9,720 (before) to 5,628 cSt (after), measured at 37.8° C., as shown in Table 1. Example 4 [0037] In a batch type reactor with capacity of about 500 ml, 200 g of a 10 °API density crude oil were introduced, together with 2 g of a microemulsion which was prepared from 50 wt. % of surfactant (sodium dodecyl-benzene-sulfonate), 35 wt. % of methanol and 15% by weight of brine with a concentration of 70,000 ppm. Next, the reactor is closed and its contents is homogeneously mixed at 300 rpm for 20 min, at 25° C. and atmospheric pressure. Subsequently, the product is recovered and its viscosity is determined, which was found to decline from 9,720 to about 5160 cSt, measured at 37.8° C., as shown in Table 1. Example 5 [0038] In a batch type reactor with capacity of 500 ml, 150 g of a 10°API crude oil are placed together with 2.5 g of a micro emulsion, which was made of 60 wt. % surfactant (sodium dodecyl-benzene-sulfonate), 25 wt.% pentan-1-ol and 15% by weight of brine with a concentration of 70,000 ppm weight of anhydrous sodium chloride. Next, the reactor is closed and its contents homogeneously mixed at 300 rpm for 20 min. at of 25° C. and atmospheric pressure Subsequently, the product is recovered and its viscosity is determined, which indicates a decline from 9,720 to 4,503 cSt, measured at 37.8° C., as shown in Table 1.
A microemulsion is formulated with a surfactant, a co-surfactant and brine, for recovery of heavy and extra-heavy crude oils by reducing the viscosity of such crude oils and improving their rheological properties for production and pipeline transportation.
2
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims benefit to U.S. Provisional Pat. Appl. Ser. No. 60/794,283, filed Apr. 21, 2006, which is incorporated by reference in its entirety. BACKGROUND [0002] 1. Field of Invention [0003] The present invention relates to projection screens and methods of making projection screens. [0004] 2. Related Art [0005] In general, a projection display can be divided into a front projection type screen and a rear projection type screen. In the front projection type screen, an image is projected from a projector onto the front projection type screen. The image is displayed on the screen. The size of the front projection type screen is typically much greater than the rear projection type screen. In contrast, the rear projection type screen, which is usually adopted in typical projection televisions exhibits, provides superior image quality compared to the front projection type. [0006] Conventional front projection screens typically have a smooth white coating on the screen surface that reflects incident light from the projector in all directions in a substantially uniform manner. With such a screen, the viewing angle increases while brightness of the screen decreases. Another type of screen has glass beads or other similar structures distributed and coated on a screen surface. Incident light is reflected at an angle from the glass beads and the resulting image is brighter within a limited viewing distance. However, because light is reflected at different angles, the brightness and quality uniformity may not be uniform at different viewing angles and distances. Also, diffused reflection occurs as disturbance light overlaps the light emitted from a projector, resulting in reduced contrast levels. [0007] Furthermore, standard projection screens on the market today are coated with a colored coating (or non-transparent), such as white or gray. In high ambient light environments, a white screen surface practically filters all projected images with a white color. In general, the effect is called a “wash out”. Similarly, a gray color-coated screen surface filters all projected images with a gray color, resulting in a degraded image, such as lower brightness, contrast, and/or color. [0008] Therefore, there is a need for a projection screen that overcomes the disadvantages as discussed above with conventional projection screens providing higher image fidelity in various ambient light conditions. SUMMARY [0009] According to one aspect of the present invention, a projection screen includes a coating of irregularly-shaped flakes or pigments adhered to a substrate. The flakes both reflect and refract light. The flakes are approximately planar or flat in one embodiment. The flakes are mixed with a non-colored, clear adhesive, resulting in an imaging layer or coating that can reflect and refract light, with the amount of refraction and reflection depending on the shape of flakes. In one embodiment, imaging layer is applied to the back of a substrate. An anti-glare coating, such as a LEXAN® matte film (e.g., 8A13F or 8B35) from GE, is applied to the top of the substrate. In a second embodiment, the flakes are mixed with a clear adhesive and a matting or glare-reducing agent, such as wax, and then applied to the front of the substrate. In a third embodiment, the imaging layer is applied to the front of a substrate. An anti-glare or matte film/coating is then applied on the imaging layer. [0010] The flakes can be aluminum or other reflective material. In one embodiment, the flakes have a high degree of irregularity, e.g., shaped like a “corn flake” with many irregular-shaped protrusions. In another embodiment, the flakes are more orderly, e.g., a more curved or rounded shape, with less irregular-shaped protrusions. If the flakes are more irregular, refraction increases, while more regularly shaped flakes have higher reflection. Thus, the imaging layer or coating can be formed with one type of flake or a combination of two or more different types, depending on screen requirements and desired reflection to refraction ratios. The density of the flake or flakes can also be varied to alter the reflection to refraction ratio. [0011] Another aspect of the present invention provides methods for making a projection screen. In one embodiment, the irregularly-shaped flakes are first mixed with a clear adhesive to form an imaging layer or coating. The imaging layer is then coated onto a back of a transparent substrate. An anti-glare or matte film/coating is formed on the front of the substrate. [0012] In another embodiment, the flakes are mixed with the clear adhesive and an anti-glare agent, such as wax or other industrial matting agents. The resulting mixture is then coated onto the front of the substrate. [0013] In yet another embodiment, the flakes are mixed with the clear adhesive and coated onto the front of the substrate. An anti-glare material or matte film is then formed or deposited or coated over the layer of flakes. [0014] Due to the shape of the flakes, the imaging layer formed by the flakes reflect as well as refract maximum intensity of the projected image, so that the maximum gain and contrast of projected images can be viewed with optimum quality without using a colored coating such as white or gray. Thus, such a projection screen enables the projected image to be seen in high ambient light environment in its original form, as well as providing the optimal color fidelity and view angle. The reflectivity and refractivity of the projection screen can be optimized by adjusting the density and mixing ratio of different types or shapes of the flakes and applying various light processing treatments to the coating surface without using a colored coating such as white or gray. [0015] This invention will be more fully understood in light of the following detailed description taken together with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIGS. 1A-1C show three types of flakes for forming an imaging layer or film according to different embodiments. [0017] FIGS. 2A and 2B are side sectional views of steps to manufacture a projection screen according to one embodiment. [0018] FIG. 3 is a side sectional view of a projection screen according to one embodiment. [0019] FIGS. 4A and 4B are side sectional views of steps to manufacture a projection screen according to another embodiment. [0020] FIGS. 5A and 5B are side sectional views of steps to manufacture a projection screen according to another embodiment. [0021] It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures. DETAILED DESCRIPTION [0022] According to one aspect of the invention, irregularly-shaped flakes, which are approximately planar or flat, are mixed with an adhesive to form an imaging layer or coating for a projection screen. The flakes can be aluminum or any other suitable material that both reflects and refracts light. [0023] FIG. 1A shows one type of flake 100 suitable for use. Flakes 100 have a relatively smooth contour, with a low occurrence of irregular protrusions. One suitable type of flake is the “silver dollar” pigment from the Alushine Series from Schlenk Metallpulver GmbH & Co. KG of Germany. [0024] FIG. 1B shows a second type of flake 102 that is also suitable for use. Flakes 102 have a more irregular shape than flakes 100 and have more irregular protrusions along its outer edges. One suitable type of flake 102 is the “corn flake” pigment from the Alucar Series from Schlenk. [0025] FIG. 1C shows a third type of flake 104 that can be used in the present invention. Flakes 104 are vacuum metallized pigments (or VMP), which are commonly known in the art. VMP flakes provide different reflection and refraction characteristics from “silver dollar” pigments or “corn flake” pigments. Typically, they have a high reflection to refraction ratio, resulting in the pigments behaving more like a mirror than a screen. However, depending on system requirements, a manufacturer may want to use VMP flakes. [0026] In one embodiment, the flakes range in size between approximately 8 and 35 microns. The surface of the flakes can be polished, such that impinging light is highly reflected from the surface. The irregular edges of the flakes enable light to be refracted. As the edges become more irregular, refraction increases, but reflection decreases. Thus, depending on screen requirements, a mixture of all “snowflake” pigments, all “corn flake” pigments, all VMP pigments, or a mixture of these or other types of flakes in various compositions and densities can be used to manufacture the projection screen. [0027] FIGS. 2A and 2B are side sectional views showing processing steps in manufacturing a projection screen 200 according to one embodiment. First, in FIG. 2A , a substrate 202 is provided, which can be either a clear or non-clear material. In one embodiment, the substrate is formed of a polycarbonate resin thermoplastic, such as Lexan® from GE Plastics, and in particular, Lexan® 8A13F or 8B35. In other embodiments, the material can be polyester or vinyl banner. The thickness of substrate 202 can vary, depending on screen and system requirements. Obviously, a thinner substrate will be lighter, but maybe not as sturdy. In one embodiment, the thickness ranges between approximately 0.005″ and 0.025″, although other thicknesses may also be suitable. [0028] Next, an imaging layer or coating 204 is applied on the front surface of substrate 202 . Application can be by any suitable process, such as, but not limited to, vacuum deposition or a granure cylindrical printing, or screen printing, or an inkjet printing process. In one embodiment, imaging coating 204 is manufactured by mixing the flakes described above with a clear (e.g., non-colored) bonding agent or adhesive and a glare reducing agent. For the clear adhesive, a clear overprint, such as the PD-C50 or PD-E50 from Coates Screen of St. Charles, Ill., can be used, such as for coating a polycarbonate substrate with UV curing. A clear vinyl banner ink, such as the VYB-E50 from Coates Screen, for a vinyl banner substrate. For the glare reducing agent, a wax or any other suitable industrial matting agent can be used. [0029] In one embodiment, the flakes are first mixed with the clear adhesive, with a ratio, by weight of 10% to 25% flake to adhesive. In one embodiment, the ratio is approximately 17% by weight. Next, the glare reducing agent is mixed in. In one embodiment, the amount is 5% to 30% by weight, such as 20%. This results in coating 204 that is reflective, refractive, and glare reducing. This mixture can then be applied to the front surface of substrate 202 , resulting in projection screen 200 in FIG. 2B . In the case of coating with screen-printing process, a printing screen-mesh of 300 or in the range of 190 to 400 mesh is used. [0030] The imaging layer 204 can also be applied to the back surface of substrate 202 in another embodiment of a projection screen 300 , as shown in FIG. 3 . [0031] FIGS. 4A and 4B are steps showing manufacture of another embodiment of the present invention. In FIG. 4A , substrate 202 is first provided. Substrate 202 can be provided with a matte or smooth surface, such as the 8A13F or 8B35 Lexan products from GE Plastics, or a glare reducing coating 400 can be applied to the front surface of substrate 202 . Glare reducing coating 400 can be any conventional anti-glare or matting layer whether extruded, pressed on or coated. In FIG. 4B , a mixture 402 of the flakes and clear adhesive is formed on the back surface of substrate 202 , such as described above, but without the glare reducing agent. Mixture 402 is both refracting and reflecting. If glare reduction coating 400 is formed on front surface of substrate 202 , the order of formation can be before or after forming mixture 402 on the back surface. [0032] FIGS. 5A and 5B are side views showing a process for manufacturing a projection screen 500 according to another embodiment. In FIG. 5A , mixture 402 is applied to the front surface of substrate 202 . Next, a matte or glare reducing coating 400 is applied to mixture 402 , resulting in projection screen 500 . [0033] Projection screens of the present invention utilize a reflective/refractive coating comprised of substantially planar irregular shaped pigments or flakes, which provide both high reflectivity and refractivity. The pigments cover the substrate so that disadvantages associated with colored coating, such as white or gray, are not present with this projection screen. Flexibility is also increased, as the manufacturer can adjust the density and/or type of pigment according to desired performance requirements of the screen. For example, using a majority or all of the “silver dollar” pigments results in a screen with higher reflectivity. Viewing angle can also be increased due to the refractivity of the screen. [0034] Having thus described embodiments of the present invention, persons skilled in the art will recognize that changes may be made in form and detail without departing from the scope of the invention. Thus the invention is limited only by the following claims.
A surface of a substrate is coated with a mixture of substantially planar irregular shaped pigments and a clear non-colored adhesive liquid. The pigments are efficient in both reflection (off the substantially planar surface) and refraction (from the irregular shaped edges). The substrate is coated, such that wash outs do not occur due to white or grey color in the coating or screen surface. A glare reducing material can be mixed in with the coating, which both reflects and refracts light, or the material can be applied as a separate layer.
8
BACKGROUND OF THE INVENTION This relates in general to improvements in rain gutters attached to residences and other buildings, more particularly to a method and attachment for maintaining such rain gutters free from foreign debris, such as twigs, leaves, pine needles, and the like, which tend to collect therein and clog the gutters. Many devices, such as slotted or perforated metal sheets, or screens of wire or other material, or plastic foam, have been used in the prior art to cover the open tops of the gutters to filter out foreign material and prevent it from entering the gutter. Success with such devices has been limited because small pieces of foreign material, and even long pine needles are allowed to enter into the gutter and accumulate, thereby clogging the gutter drain, stopping the flow of water. Hence, it is still necessary at intervals to open and clean the gutter. Also, several of these prior art types of covers are difficult and time consuming to install and remove. Accordingly, it is a principal object of the invention to provide a gutter combination or attachment which substantially eliminates the necessity to open and clean the gutter. Another object is to provide gutter filtering means which is readily installed, and easily removed, if circumstances require it. These, and other objects are realized in accordance with the present invention in a gutter filter attachment which comprises a screen with a coarse fiber glass lining attached to the underside of the screen. The screen is installed onto the gutter by means of resilient metal or plastic gutter straps equipped with clips which are fitted onto the end of the straps. The clip end of the gutter strap simply snaps into the screen; and the other end of the strap is bent outward, bearing against the inside rear wall of the gutter, thereby applying a downward pressure on the screen, holding it tightly against the gutter and the roof. A desired amount of pressure against the gutter and the roof may be achieved by simply adjusting the position of the clips in the screen. The gutter filter attachment of the present invention has the advantage that it filters out even small pieces of foreign material, so that there is virtually no build-up of debris in the gutter, requiring the gutter to be periodically opened and cleaned. Another advantage of the gutter filter of the present invention is its ease of installation. These, and other objects, features and advantages will be apparent in a study of the detailed specification hereinafter with reference to the attached drawings. SHORT DESCRIPTION OF THE DRAWINGS FIG. 1 is a rear perspective showing, partially broken away, of the rain gutter filter attachment of the present invention; installed on a convential gutter. FIG. 2 is an exploded view, partially broken away, of the rain gutter filter attachment of the combination of FIG. 1 being removed from the gutter; FIG. 3 is a cross-sectional view of the typical rain gutter of FIGS. 1 and 2, in place on the wall of a building; FIG. 4 is a cross-sectional view through the plane indicated by the arrows 4--4 of FIG. 1, of the rain gutter filter attachment of FIGS. 1 and 2, in place on a gutter; FIG. 5 is a fragmentary top view of the rain gutter filter attachment of FIGS. 1 et seq. removed from the gutter; FIG. 6 is a fragmentary front view of the rain gutter filter attachment of FIGS. 1 et seq. removed from the gutter; FIG. 7 is a fragmentary bottom view of the filter attachment of FIGS. 1 et seq. removed from the gutter; FIG. 8 is a fragmentary rear view of the filter attachment of FIGS. 1 et seq. removed from the gutter; FIG. 9 is an enlarged fragment of the sectional view of FIG. 5, showing the clip joined to the filter attachment; and FIG. 10 is a sectional view through a plane indicated by the arrows 10--10 of FIG. 5 of the filter attachment of FIGS. 1 et seq.; DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a fragment of a gutter assembly as it would be disposed on the outside wall of a residence or other building. (See FIGS. 3 and 4). In accordance with the present invention, the gutter assembly 1, as shown in FIG. 1, comprises a conventional gutter 2, preferably of sheet metal, such as aluminum. In the embodiment under description, the gutter 1 is a hollow structure comprising a flat rectangular base plate 2d, 31/4 inches wide, and of a length necessary to be accommodated on the sidewall 10b below the eaves 10a of a residence, or other structure, on which it is mounted. The back plate 2c of the gutter is of matching length, and is welded or otherwise secured, in vertical normal relation to the rear edge of the base plate 2d. The flat plate 2e at one end, and a matching plate, not shown, at the opposite end, are welded, or otherwise secured, in normal relation to the lateral edges of the base plate 2d and the back plate 2c. The side plate 2e is flat along the bottom edge, 31/4 inches wide, to conform to the width of base plate 2d, and has a curved outer wall 2f, which forms an outwardly projecting lip 2g. The elongated outwardly-curved front plate 2h is welded, or otherwise secured, along the front edge of the base plate 2d, supported at its ends beween the flat end plate 2e and the matching end plate on the other end. Alternatively, back plate 2c, base plate 2d and the outwardly-curved front plate 2h can be formed integrally, from a single metal sheet, to form an open trough, say, 31/4 inches across the bottom, and 5 inches across the open top. Respectively extending above the top front edge of the front lip 2g adjacent to the open end of the gutter 2, is a half-inch wide flange 2a which runs the length of the gutter, and which is constructed to fold inward flat to accommodate and hold in place the front edge of filter attachment 3-8, so that the latter completely covers the open top of gutter 2, the inner edge resting on the front edge of the roof 10a. In spaced-apart positions along the length of the gutter 2, spaced-apart say, 91/4 inches, are nails 6 which pass through sleeves 6a disposed across the width of the gutter 2 from front to back, the ends of the nails 6 fastened into the sidewall 10b of the building to hold gutter 2 in place. The screen 3, for the purposes of the present invention, may be formed of galvanized steel wire, vinyl-coated steel wire, aluminum wire, or plastic mesh. The openings may range in sizes from 1/4 inch to 1/2 inch squares. In the present embodiment, the screen 3 is flat, just under 5 inches wide, formed of 0.028 inch diameter steel wire, woven into squares having 1/4 inch openings. Screen 3 covers the full length of the gutter 2. A particular feature of the present invention is a filter pad 8, the same length and width as the screen 3, which is fastened in contiguous relation beneath the screen, forming the filter attachment 3-8. In the present embodiment, this pad 8 is made of a layer, say, 3/8 inch thick of a material known as fiber glass. It is contemplated that the filter pad 8 may assume any thickness of between say, 3/8 inch and 1 inch for the purposes of this invention. The fiber glass pad 8 is clamped in place beneath the screen 3 along its lateral edges by means of a pair of flat elongated metal molding clamps, 3a, 3b, having upper and lower jaws, say, 1/2 inch wide, which, for the purposes of the present invention, may be formed of strips of aluminum, plastic, vinyl, vinly-coated steel or galvanized steel. Assembly of the screen 3 and the fiber glass pad 8, known as the `filter attachment`, is held together by the lateral molding clamps 3a and 3b. Filter attachment 3-8 is disposed to be slideably installed in place beneath the flange 2a so that the latter is held in place on, and completely covers the top opening of the gutter 2, with the inner edge resting on the roof 10a, as previously stated. The filter attachment 3-8 is further held in place by an assembly of resilient straps and clips 4 and 5, disposed in spaced-apart relation at intervals of, say, anywhere from 8 to 12 inches, along its length. The straps 4 and 5, and any additional straps used, depending on the length of the gutter, are formed of resilient plastic, stainless steel, or vinyl-coated spring steel, say, 1 inch wide, and 6 inches long. Near the inner end are round screw holes which accommodate resilient snap buttons 4a, 5a, which may be formed of nylon or resilient plastic, and are snapped into place through an opening in the screen 3 to hold the upper ends of the straps 4, 5 against the underside of the screen assembly 3-8, as shown in FIG. 10. Centered in the straps 4, 5, about 1/2 inch beyond each of the screws 4a, 5a, are two additional parallel slots, spaced-apart, say, 1/2 inch, which respectively accommodate clips 4b, 5b, formed of say, stainless steel, vinyl-coated steel, or plastic, which is the same material as that of straps 4, 5. The clips 4b, 5b are say, 1/4 inch wide, and are U-shaped with short flanges, extending, say, about 3/8 inch from the inner and outer ends. The clips 4b, 5b respectively fit into the two parallel slots in strips 4, 5, with the bottom of the U in contact with the under surface of straps 4, 5, so that the inner flange is secured between the underside of screen 3, and the upper face of respective strap; and outer flange extends with its free end forming a hook passing through one of the screen openings and resting on the upper surface of screen 3. Alternatively, it is contemplated that the straps 4 and 5, and the clips 4a, 5a can be formed integrally, of a single continuous piece. When the filter attachment 3-8 has been installed in place, covering the upper opening of the gutter 2, the straps 4 and 5 bear against the rear inside wall 2c of the gutter 2, thereby holding the screen assembly 3-8 firmly pressed in place beneath the inwardly-directed flanges 2a, 2b which run the length of the gutter 2. It will be understood that the pressure against the inside backwall 2c of the gutter 2 can be varied by changing the positions of the buttons 4a, 5a and clips 4b, 5b across the width of the screen 3. While the invention has been described with reference to a specific embodiment, it will be understood that the invention is not limited to the specific structures or dimensions described herein by way of illustration, but only as defined in the claims hereinafter.
This relates to an improvement for rain gutters comprising a filter attachment which is constructed to fit over the open end of the gutter. The filter attachment comprises an elongated screen to the underside of which is clamped a pad of fibrous material such as fiber glass. Adjustable clamping means is provided for holding the filter attachment in place on the gutter opening.
4
FIELD OF THE INVENTION This invention relates to a bat, for use as a training aid for ball games, in particular for soccer (Association Football). BACKGROUND OF THE INVENTION The main type of soccer training which can be carried out by a person practising on their own relates to ball control skills, where the ball is kept under close control with the feet and/or the head, and it is widely acknowledged that this type of training is very useful in developing soccer skills. Carrying out such practice on one's own can however be frustrating, particularly for those less skilled because if the ball is not properly controlled, it will roll or bounce away from the player who will have to spend time retrieving it before the exercise can be started again. Recognising this problem, several soccer training devices have been designed to assist in this type of soccer practice. These devices all work by attaching a line to the ball, and either attaching the other end to the player (for example by a belt) or having the player hold the other end of the line whilst he or she is practising. In some of these training devices, the line is attached to the ball by placing the ball in a string bag attached to the end of the line. Although such devices are commercially successful, they have significant disadvantages. Firstly, because the ball is tethered, it is not free to move in entirely the same way as an untethered ball. Secondly, the presence of a string bag around the ball means that the contact between the player's foot and the ball is distorted. Thirdly, there is a danger that the tether line may become caught around the player's legs or entangled with itself or with other objects. Fourthly, if the ball is kicked hard, it can rebound and strike the player which is not always desirable. SUMMARY OF THE INVENTION Baseball bats are known from, for example, U.S. Pat. Nos. 4,836,541 and 4,951,948 and 5,456,461. It is of the essence both in the game of baseball and in practice for that game, that the bat be swung at the ball so that the ball can be hit a long distance by the batsman. This is of no assistance in soccer training. The present invention seeks to overcome some or all of these difficulties, and provides a bat for use as a training aid for ball games, the bat being generally elongate in form, with a grip portion at one end and a rotationally symmetric elongate playing surface extending from the grip portion to the opposite end, the playing surface increasing in diameter as it extends from the grip portion to the opposite end, with the point of greatest diameter being at the opposite end and there being a shoulder at the opposite end at which the diameter of the bat increases substantially relative to the diameter of the major part of the length of the bat. With such a bat, a player wishing to practice soccer skills alone can use an untethered ball and will hold the bat in one hand, whilst kicking or heading the ball. If the ball goes out of control, it can be tapped back towards the player by hitting it with the bat, the playing or hitting surface of which is designed so that a ball which is hit by the bat will tend to be diverted towards the player. The presence of a shoulder at the remote end of the bat encourages this. The player could use two bats, one in each hand. In one embodiment, the playing surface is in the form of a right circular cone, with a cone angle of between 5° and 15°. However the playing surface may alternatively be in the form of a trumpet shape so that, when seen in cross section, the sides of the playing surface are concave and there is a substanstial increase in diameter at the remote end, and there is a substantial increase in diameter at the remote end. The playing surface is preferably covered with a high friction coating, such as a rubber coating, so that when a ball is hit the ball does not slide on the surface. This will make it easier for the player to ensure that when he hits the ball, the ball is directed back towards himself. This surface should preferably be non-absorbent. The opposite end of the bat may have a removable end cap, the cap forming the point of largest diameter of the bat. The cap may screw onto a threaded boss on the end of the bat, and the peripheral walls of the cap may be parallel sided, or tapering to merge with the tapered playing surface of the bat. The bat may have an interior cavity, and access to this cavity can be had by removing the end cap. If desired, the cavity can be filled with a weighting material (such as water or sand) to achieve a desired balance for the player. It may be desirable for the contours of the end cap not to merge with the tapered shape of the playing surface, but to be slightly larger in diameter to form a shoulder which will enhance the likelihood of a ball being returned to the player when hit by the bat, when the point of contact with the ball takes place at the opposite end of the bat. The bat may be made from wood, from a metal such as aluminium or, most probably, from a fibre reinforced composite. The grip portion may be constructed in the same way as the grip portion of a tennis or squash racket. The overall length-of the bat is preferably between 400 and 1000 millimetres, with the most preferred length being between 500 and 800 millimetres. Different length bats may be sold, with shorter bats being appropriate for younger children. The diameter of the playing surface at its smallest diameter may be between 30 and 40 millimetres, and at its point of greatest diameter between 100 and 200 millimetres. The most preferred dimensions are in the centre of these ranges. The invention will now be further described, by way of example, with reference to the accompanying drawings in which: DESCRIPTION OF THE DRAWINGS FIG. 1 shows a first embodiment of a bat in accordance with the invention; FIG. 2 is a partial cross section through the bat of FIG. 1; FIG. 3 shows a second embodiment of the bat in accordance with the invention; and FIG. 4 is a top view of an end cap. DESCRIPTION OF PREFERRED EMBODIMENTS The bat shown in FIG. 1 has a grip portion 10 with generally parallel sides wound with a grip, in the manner conventional for, e.g., tennis and squash rackets. The grip probably only needs to be long enough to be held by one hand as it is unlikely that a player will want to hold it with two hands. The bat has a playing surface 12 which tapers from a small diameter end at 14 to a large diameter end at 16 . In FIG. 1, the playing surface 12 is straight sided and has a constant taper angle over its length. FIG. 3 shows an alternative embodiment where the playing surface 112 has concave sides and where the taper angle continually increases from the small diameter end 114 to the large diameter end 116 . The playing surface 12 is covered with a thin layer 18 of a rubber or rubber-like material to give it high friction properties. This can be seen particularly in FIG. 2 . the surface may be a pimpled rubber surface, with the pimples facing out, as used on table tennis bats. At the large diameter end 16 , the bat has a removable base cap 20 . FIG. 2 shows how this screws onto a thread at the far end of the bat. The bat may have a hollow interior at 22 , with the hollow interior being accessible through an opening 24 after the cap 20 has been removed. The interior 22 can be used as a ballast chamber for containing the material which will add weight to the far end of the bat to vary its balance. The end cap and the chamber 22 are however not essential. The bat may be a single unitary solid body. FIG. 1 shows an end cap 20 which is parallel sided and has a diameter slightly larger than that of the end 16 of the bat, so as to form a shoulder 26 . The cap 120 in the embodiment of FIG. 3 has a tapering circumference which merges into, and continues the taper of the shape of the playing surface 112 . FIG. 4 shows that the large surface area of the base cap 20 can be printed with advertising material or a soccer club logo or any other graphic material. The bat will be used in the following way. When a player wants to practice his soccer skills alone, he will take an ordinary soccer and the bat. The bat will be held in one hand and will only be used if the ball goes out of control or threatens to go out of control. If this happens, the player will reach out with the bat and tap the ball to bring the ball back close to the player's body, so that it can be brought under control again. If the ball is travelling away from the player, he can simply reach out and tap it back to himself; if the ball is falling within the vicinity of a foot momentarily being used for standing on, the player can bat it into the air rather than try to kick it. If the ball is out of control and bouncing away, a swift tap towards the ground will generally send it back in the player's direction. One of the main advantages of this bat as a soccer practice aid, in comparison with the “ball on a string” aids hitherto used is that the ball itself is unrestrained. It therefore behaves in the same manner as a ball on a soccer pitch during a soccer game. Furthermore, if the player wants to vary his practice, for example, by kicking the ball against a wall, he is free to do so or if another person comes to join the practice, then the ball can be kicked between them. The bat can still be useful to recover a ball going out of control, as already described. Practice and/or play can therefore easily be arranged into activities with partners or in groups. The bat requires no setting up and is extremely flexible in the manner of its use. The user might choose to practice some particular skill alone, but then remains entirely free to pass to a partner or a try a shot or dribble, in order to introduce variety. Some soccer skills may be practiced with this bat which cannot be practised in any other way (or at least not without assistance). The foremost attributes of the bat are those related to maintaining control of the ball and of recovering the ball after control has been lost. However the bat can also enhance activity with a ball, in tems of the user's own enjoyment and in terms of a benefit in the skill acquisition process. Certain moves and ball drills become possible with a hand-held bat which are not possible without a bat. In short, the bat is an extremely versatile and user-friendly device whether used seriously to develop a particular soccer skill, or simply for the fun of it. It allows the user to exert manual control over the ball, while providing a more suitable surface than his own arm or hand and avoiding any conceptual difficulties which he might have with “handling” the ball in a soccer setting.
A bat has a grip portion and an elongate, rotationally symmetric playing surface. The playing surface continuously increases in diameter towards its outer end, and the outer end is the widest part of the bat. The surface can be covered with a friction-enhancing material. The bat can be used, together with a conventional soccer ball, as a soccer practice aid.
0
This application claims priority from provisional application Ser. No. 60/143,140 filed Jul. 8, 1999, the disclosure of which is incorporated herein by reference. The present invention relates to items which include a puzzle where the puzzle pieces adhere via pressure sensitive adhesive to a backing sheet. More particularly, the invention relates to two-sided puzzles of this type that are designed to be sent to an ultimate recipient; such puzzles might carry a scrambled message or a visual display. As such, they might be used for advertising or promotional materials or sold as novel postcards or the like. BACKGROUND OF THE INVENTION Sophisticated jigsaw puzzles have previously been marketed in which many of the pieces are of the same size and shape so as the person “making” or assembling the puzzle is often required to rely only upon the portion of the picture carried by the front face of the individual puzzle piece to assess whether it is in the right position to complete the pictorial display. The concept of interchangeable pieces has also been used in simpler puzzles designed for promotional or advertising purposes or the like where a pictorial display, that may or may not also include a written message, is supplied to a recipient in a scrambled form in order to induce the curious recipient to rearrange the pieces to solve the puzzle and in this manner be exposed to the message. An example of such promotional puzzles is found in U.S. Pat. No. 4,336,664 (1982). This patent illustrates a label that is made of a lamination of two sheets held together by pressure-sensitive adhesive wherein a puzzle in scrambled form is printed in a circular frame region on the front sheet. The frame is divided into three identical regions of seven puzzle pieces each, with the shape of each piece in one region being different but with each piece in the region having two counterparts, one in each of the other regions. To facilitate solving the puzzle, a separate circular frame is provided on another section of the label. The puzzle piece, when removed from its original orientation, carries pressure-sensitive adhesive on its rear surface and can then be immediately placed onto the adjacent frame having the hopefully correct orientation as a step in solving the puzzle. Such types of novel items that can be used for advertising and promotional purposes have proved popular, and there has been interest in providing improvements in this general theme. Accordingly, efforts have been made to develop other designs of relatively simple puzzles that can use pressure-sensitive adhesive to advantage in a novel item of this general character. SUMMARY OF THE INVENTION The invention associates a transparent backing sheet with a multi-piece puzzle wherein both faces of the puzzle pieces are utilized. Two-sided puzzle items of this general type are designed to be sent to recipients, e.g. as advertising material or simply postcards, and may include a transparent backing sheet having a frame region wherein a set of puzzle pieces are positioned. The puzzle pieces interfit with one another so as to substantially fill the frame region, and at least some of them are identical in size and shape. Pressure-sensitive adhesive is used to detachably adhere the set of pieces to the front surface of the backing sheet. The front faces of the set of puzzle pieces may be substantially blank, may contain a composite pictorial display or may contain a composite message, whereas the rear faces contain either a different composite message or a different composite pictorial display. When the puzzle item is distributed to the ultimate recipient, the set of puzzle pieces is arranged so that at least one of the sets of front and rear puzzle piece faces is scrambled and thus not comprehensible. The nature of the item is such that the puzzle pieces can be removed one-by-one and reassembled, preferably on the rear surface of the backing sheet, by the recipient, who may be guided in achieving such reassembly by the representations on the front faces of the pieces. For example, the front faces may have a scrambled pictorial display that is then assembled in the manner of the usual jigsaw puzzle. Alternatively, each of the pieces may contain indicia on its front face which would direct the recipient to place the piece at a specific correspondingly shaped location on the rear surface of the backing sheet in the region of the frame. Once the reassembly of the pieces is completed, the message or pictorial display printed on the rear faces of the pieces has become comprehensible, and it can be viewed through the transparent backing sheet. In one preferred embodiment considered to be particularly suited for advertising and promotional purposes, or alternatively for use as a game, the front faces of the set of puzzle pieces may have a pictorial display printed thereon, whereas the rear faces thereof contain an advertising or promotional message. In the initial orientation in which the item is distributed, both sets of puzzle piece faces are scrambled. When the pieces are reassembled so that the pictorial display on the front faces becomes comprehensible, the message on the rear faces is also comprehensible and is viewed through the transparent backing sheet. In another preferred embodiment, the novelty item is created to be sold as a postcard, with the rear faces of the pieces containing an attractive picture of a local landmark or the like in scrambled condition. The front faces may provide a large blank space so as to facilitate the writing of a short greeting and message to the recipient. After the recipient reads the message and reassembles the pieces, perhaps guided by indicia printed in a corner of the front face of each piece, the rear faces of the pieces have now become assembled into the correct orientation so that the local landmark is now visible through the transparent backing sheet. In another alternative, the front faces may contain a printed message related to the geographical area plus space to write a brief message, and the pictorial display on the rear faces may become unscrambled. After adding the message to the kiss-cut pieces, the sender removes all of the pieces and replaces them in scrambled orientation. The card would contain a direction telling the recipient to unscramble the puzzle pieces in order to read the message. In still another preferred embodiment, a two-sided puzzle item is provided which comprises first and second sheets both of which are printed on their front and rear surfaces. The two sheets are joined together in a face-to-face lamination wherein the inside surfaces are attached to each other by adhesive which includes at least a major region of pressure sensitive adhesive. A set of interfitting puzzle pieces is die-cut in adjacent sections of each of the sheets, which puzzle pieces are detachably attached to the inside surface of the other sheet in a first scrambled orientation, with at least some of said puzzle pieces being identical in size and shape. The set of scrambled puzzle pieces die-cut from the first sheet is originally positioned upon and attached to a printed section of the inside surface of the second sheet that contains a first visage, while the set of scrambled puzzle pieces die-cut in the second sheet is originally positioned upon and attached to a printed section of the second sheet that contains a second visage. The scrambled pieces can be removed so as to expose each of the first and second visages and then reassembled upon the respective outside surfaces of the sheets by attachment via the pressure-sensitive adhesive so as to respectively either complete or complement both of the visages. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front view of an item embodying various features of the invention wherein a plurality of puzzle pieces are arranged in scrambled condition on the front surface of a transparent backing sheet. FIG. 2 is a rear view of the item of FIG. 1 which illustrates how the item appears from the rear when viewed through the transparent ba cking sheet. FIG. 3 is a view of the transparent backing sheet from the rear which illustrates the markings that delineate locations where correspondingly marked puzzle pieces should be placed in order to correctly solve the puzzle. FIG. 4 is a view similar to FIG. 1 showing the puzzle pieces rearranged so that the pictorial display becomes comprehensible. FIG. 5 is a view similar to FIG. 2 which shows the scrambled message of FIG. 2 in comprehensible form. FIG. 6 is a front view, similar to FIG. 1, of an alternative item embodying various features of the invention designed in the form of a postcard to be sent through the mail. FIG. 7 is a rear view of the item shown in FIG. 6 . FIG. 8 is a view similar to FIG. 6 with the puzzle pieces rearranged so the pictorial visage is comprehensible. FIGS. 9 and 10 are front and rear views of an alternative embodiment of an item similar to that of FIG. 6 where the item is originally printed with the pictorial visage on the front of the card in unscrambled condition, with FIG. 9 carrying an exemplary message written by the sender. FIG. 11 is a view of the rear of the item of FIG. 9 showing the scrambled message after the sender has written the message and then removed and replaced all of the puzzle pieces to scramble both the pictorial display and the message. FIGS. 12-15 are views of the front and rear surfaces of two sheets which are printed on both front and rear surfaces and which are intended to be laminated to each other, with FIGS. 13 and 14 representing the two inside surfaces that will be in face-to-face contact in such lamination which provides a double puzzle arrangement embodying various features of the invention. FIG. 16 is a schematic perspective view of an alternative embodiment of a double puzzle arrangement generally similar to that depicted in FIGS. 12-15. FIG. 17 is a perspective view of the FIG. 16 embodiment following unscrambling by the recipient. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 illustrates an item 11 which may be used for promotions or advertising and which is rectangular in shape and includes an upper region 13 that serves as a frame for a pictorial display or the like and a lower separate section 15 that provides space for a promotional message or the like. By frame or frame region is meant the definition of a specific area in which the interfitting puzzle pieces will be reassembled. The item 11 is a lamination of a transparent backing sheet 17 (FIG. 3) and an opaque main sheet 19 that is printed on both sides. The rear surface of the main sheet 19 is laminated to the front surface of the backing sheet 17 by clear pressure-sensitive adhesive. Prior to lamination, either one of the two surfaces is coated with a release coating, e.g. a silicone of the usual character well known in this art, so that the pressure-sensitive adhesive will adhere preferentially to the other surface. The two options are explained hereinafter. Following lamination of the printed main sheet 19 and the backing sheet 17 , a kiss-cutting operation is carried out, as well known in this art, in order to create a plurality of interfitting puzzle pieces 21 in the frame section 13 of the sheet. In the illustrated embodiment, the sheet 19 is printed so that the puzzle pieces are arranged in a scrambled condition so the pictorial display is incomprehensible. As can be seen from FIG. 2, the rear surfaces 25 of the puzzle pieces 21 are printed with a written message which is likewise present in scrambled condition. As best seen in FIG. 3, if desired, the transparent backing sheet 17 can be printed with a grid 27 to assist the recipient in reassembling the puzzle pieces 21 with the correct orientation. As a further option, the grid can include indicia 29 , such as numbers or letters, that would correspond to numbers or letters printed on the puzzle pieces 21 that would direct the recipient to place a particular puzzle piece in the correct location in order to easily solve the puzzle. The item 11 may be used as a game, but is designed particularly for use as an advertising or promotional item which would usually include the name of the vendor on the front surface of the main sheet 19 , in this instance, in the lower section 15 , which may likewise contain a direction such as “Solve puzzle and win”. The recipient of the promotional item would then remove the eight puzzle pieces from the front surface of the transparent backing sheet 17 and then individually rearrange them to create a comprehensible visual display in unscrambled condition. Such is depicted in FIG. 4 where the display is one of a race car. The printing of the front side and the rear side of the main sheet 19 is such that, when the puzzle pieces 21 have been reassembled so that the front surfaces provide the comprehensible visual display, the message carried by the rear surfaces of the puzzle pieces is also assembled in comprehensible manner, as shown in FIG. 5 . The rear surface of the lower portion 15 of the main sheet could be fitted with a suitable explanatory legend such as “You have won” with the sentence being completed by the unscrambled message on the rear surfaces of the puzzle pieces 21 . In the instance where the rear surface of the puzzle pieces 21 is coated with a release coating, the clear pressure-sensitive adhesive will adhere to the front surface of the transparent backing sheet 17 and accordingly in reassembling the pieces to create the comprehensible pictorial display, the puzzle pieces will be returned and placed on the front surface of the backing sheet 17 in the correct orientation. Once the reassembly is complete, because the backing sheet 17 is transparent, the recipient would turn the item over and would view the message informing him or her the prize that had been won. As an alternative, the rear surface of the backing sheet 17 could also be coated with pressure-sensitive adhesive in the region of the frame and covered with a release liner that could be clear or opaque and optionally printed. The recipient could then be instructed to remove the pieces, switch the release liner from rear to front, and carry out the reassembly on the rear surface. If instead the front surface of the transparent backing sheet 17 was coated with the release coating, the pressure-sensitive adhesive would adhere to the rear surfaces of the puzzle pieces 21 and, if desired, they could again be reassembled on the front surface in the same manner as previously indicated. However, the pieces 21 could be removed one by one and applied one by one to the rear surface of the transparent backing sheet 17 if desired in this situation so that only one puzzle piece need be separated from the item at a time, thus perhaps simplifying the reassembly. Moreover, in order to further simplify the task, indicia 29 , i.e. the numbers 1 - 8 , could be applied to the rear surfaces of the puzzle pieces 21 to assist the recipient in the reassembly of the puzzle. In such a situation instead of having to rely upon the pictorial display, the recipient could simply match the number on the rear surface 25 of a puzzle piece with the indicia 29 on the grid and place the piece in that location. Under such circumstances, the pictorial display would now appear in its comprehensible arrangement on the rear surface of the transparent backing sheet and by turning the piece over the prize that had been won would be known by reading the now comprehensible message through the front surface of the transparent backing sheet. As a further option, if desired in order to provide still further area for advertising or promotional text, the transparent backing sheet 17 might be made either twice as wide or twice as high, with the printed grid 27 being located either alongside or above or below the frame region 13 of the main sheet. In such an instance, the release coating would be applied to the transparent sheet so that the pressure-sensitive adhesive would adhere to the rear surface of the puzzle pieces 21 . The recipient could then reassemble the puzzle, as for example, next to the original frame on the grid that is provided to create the comprehensible pictorial display. Again, simply turning the item over would allow the recipient to read the message which would indicate what prize had been won. Illustrated in FIGS. 6-8 is an alternative embodiment of a novelty item of this general type in the form of a postcard 31 . Again, the item consists of an opaque sheet 33 that is printed on both surfaces that is laminated by pressure-sensitive adhesive to a transparent backing sheet 35 of the same dimension. What is arbitrarily referred to as the front surface 37 of the opaque sheet 33 includes a right-hand section similar to what is found on the usual postcard with a space upon which to write the name and address of the recipient and affix the appropriate postage. The left-hand section of the main sheet is die-cut into a plurality, e.g. 16, total pieces 39 . The rear surface of the printed main sheet 33 is visible (see FIG. 6) through the transparent backing sheet 35 . On the rear surface of the address portion of the sheet, a suitable legend such as “Where am I? Solve puzzle to see!” is printed. To the immediate right thereof might appear the scrambled pictorial visage representative of a particular city, area, monument, national park, etc. in the geographic region where the novelty postcards 31 would normally be sold. For example, the illustrated design is one of the well known arch on the riverfront of St. Louis which served as the gateway to the West in the 19 th Century. The purchaser of the card could then pen his greetings on the kiss-cut portion of the front surface 37 of the main sheet 33 , add the name and address of the recipient and mail the card with appropriate postage. Upon receipt, the recipient would remove the sixteen puzzle pieces 39 , after reading the message, and reassemble them so that the rear surfaces of the puzzle pieces 39 on which the pictorial display is printed would be in comprehensible orientation, as shown in FIG. 8 . If the pressure-sensitive adhesive and release coating were applied so the adhesive remains adhered to the rear surfaces of the puzzle pieces 39 , then reassembly could be carried out while viewing the pictorial display through the transparent backing sheet, reapplying the pieces 39 either onto the front surface or the rear surface of the backing sheet. Alternatively, if the release coating was applied to the rear surface of the main sheet 33 , then the pressure-sensitive adhesive would remain attached to the transparent backing sheet and the reassembly might be more simply be carried out on the front surface from which the pieces 39 were removed, so as to create the pictorial display in the region next to the name and address of the recipient where the original greeting appeared. As a still further alternative, indicia, such as small numbers or letters similar to the indicia 29 , could be printed on a grid on the transparent backing sheet 35 , and corresponding small numbers could be printed so that they would appear in corners of the sixteen die-cut square pieces 39 on which the purchaser would write his or her greeting or message. In this case, all sixteen puzzle pieces 39 could be removed and then reassembled in the orientation dictated by the corresponding indicia to again fill up all sixteen squares. Following such reassembly, the recipient would turn the postcard over and would see the intended pictorial visage through the transparent backing sheet 35 , as shown in FIG. 8 . Illustrated in FIGS. 9-11 is an alternative embodiment of a novelty postcard 41 which consists of a similar main sheet 43 that is printed on both sides and laminated to a transparent backing sheet 45 that is essentially the same as the sheet 35 . However, in this embodiment, in its original form, the pictorial visage is printed in its unscrambled condition, as seen in FIG. 10 . Following lamination, the card 41 is kiss-cut so as to create a plurality of puzzle pieces 47 in the region to the left of the address portion of the main sheet 43 . As a result, when the purchaser buys the card, he can view the pictorial visage which again is the St. Louis Arch (see FIG. 10 ). After the purchaser writes the desired message on the die-cut front surfaces of the puzzle pieces 47 , all sixteen of the puzzle pieces are removed and then arbitrarily scrambled and returned to the card as illustrated for example in FIG. 11 . Some of the pieces may be upside down and others rotated 90° in either direction, thus rendering the message incomprehensible, and of course likewise rendering the pictorial visage incomprehensible. Under these circumstances, when the recipient receives the card and notes the legend below the address, such as “Unscramble to read message”, he will then reassemble the sixteen puzzle pieces in the correct orientation in order to read the message as it was written in FIG. 9 . In so doing, the pictorial visage will be returned to its original comprehensible orientation, so the recipient can see the view which is representative of the geographical location from which the postcard was mailed. Shown in FIGS. 12-15 are the front and rear surfaces of two sheets of the same rectangular size which are both printed on their front and rear surfaces and which are designed to be laminated to each other to create a double puzzle arrangement. The sheets are referred to as a first sheet 51 and a second sheet 53 . Rather than to refer to the surfaces as the front and rear surfaces, in the context of this overall arrangement, it appears simpler to refer to the surfaces in the orientation in which they will assume in the laminated item. Therefore, FIG. 12 depicts what will be referred to as the outside surface 55 of the first sheet, and FIG. 13 depicts the inside surface 57 of the first sheet 51 . Similarly, FIG. 14 depicts the inside surface 59 of the second sheet, whereas FIG. 15 depicts the outside surface 61 thereof. Referring first to FIG. 12, the outside surface 55 of sheet 51 includes a perimeter frame 63 which surrounds 16 die-cut puzzle pieces 65 that are located in an upper rectangular region and an uncut or imperforate lower region 67 which serves as a platform section and lies within the bounds of the perimeter frame. The platform region 67 is optionally printed with a grid or other guide so as to facilitate the reassembly of the puzzle pieces 65 onto this platform section. In addition, the 16 rectangular boxes can be optionally numbered (as depicted) to further guide the recipient of the item in reassembly thereof, should such guidance be desired. FIG. 13 shows the inside surface 57 of the first sheet 51 ; this surface consists of the perimeter frame 63 , the rear surfaces of the puzzle pieces 65 (which can be optionally numbered to coincide with the numbers on section 67 ), and a lower rectangular region which is printed with an incomplete first visage 69 and which constitutes the opposite surface of the platform section 67 . The 16 puzzle pieces carry a pressure-sensitive adhesive 71 ; such is depicted by a speckled or dotted pattern in FIG. 13 . This pressure-sensitive adhesive, that is used to laminate the two sheets 51 and 53 , preferentially adheres to the rear surfaces of the puzzle pieces 65 . Consistent therewith, it should be understood that the portion of the inside surface of the first sheet that constitutes the incomplete first visage 69 would be coated with a release coating of silicone or the like so that the pressure-sensitive adhesive applied in this region to complete the lamination would release therefrom and adhere to a second set of puzzle pieces to be described hereinafter. Referring now to FIG. 14 where the inside surface 59 of the second sheet 53 is depicted, it can be seen that it has the same pattern as the inside surface 57 of the first sheet with the exception of being inverted. More specifically, the second sheet 53 contains a perimeter frame 73 and a second set of die-cut puzzle pieces 75 that are located within that perimeter frame in a rectangular region which constitutes the bottom one-half of the interior surface. The upper half of the sheet contains a printed second incomplete visage 77 . The inside surfaces of the die-cut puzzle pieces 75 are similarly covered with a speckled or dotted pattern to represent the pressure-sensitive adhesive 71 which coats these surfaces of the puzzle pieces in the lamination. The surface of the second visage 77 , similar to the first visage 69 , is coated with a release coating. Finally referring to FIG. 15, the outside surface 61 of the second sheet 53 can be seen to include the perimeter frame 73 , the 16 scrambled puzzle pieces 75 and an upper region 79 (which is the opposite surface of the second incomplete visage 77 ). This upper region 79 serves as a platform for attachment of the puzzle pieces 75 , and it can be optionally provided with a grid or other guide means to facilitate appropriate alignment of the pieces during their reassembly. In fabricating the double puzzle item, the two printed sheets 51 , 53 would first be initially coated with a silicone or other release coating in the regions of the first visage 69 and the second visage 77 . Lamination might then take place simply by totally coating one of the sheets with pressure-sensitive adhesive (PSA) and then aligning and pressing the two sheets together under pressure to effect overall joinder. Alternatively, the perimeter frame portions 63 , 73 of the sheets could be permanently joined, as by applying a high strength permanent adhesive to one of the frames and PSA to the remainder of the sheet, so as to unite the two sheets in the perimeter regions and thus give overall stability to the laminated item. Of course, depending upon the width of the legs of the frames 63 , 73 , attachment by pressure-sensitive adhesive may provide adequate rigidity and thus negate the need to differentially coat the sheet material with different adhesive patterns. Once the lamination has been effected so that the first and second sheets 51 , 53 are joined in face-to-face alignment to each other, the lamination is subjected to kiss-cutting as explained hereinbefore with respect to the item 11 . A first kiss-cutting operation would preferentially die-cut the first sheet to form the 16 puzzle pieces 65 at the location within the bounds of the perimeter frame 63 . A second kiss-cutting operation would die-cut the second sheet 53 to form the 16 puzzle pieces 75 . Using more sophisticated equipment, it may be possible to carry out the two kiss-cutting operations simultaneously, as for example while running the laminated sheet material, in web form, in a direction aligned with the shorter dimension of the individual sheets. If desired, directions or explanations with regard to the two-puzzle item could be suitably imprinted on the perimeter frames of the outside surfaces of either both of sheets 51 , 53 , or such could be imprinted within the two platform regions 67 , 79 which will be initially in full view, but ultimately become obscured upon reassembly of the scrambled puzzle pieces. When one views the laminated item, looking at the outside surface 55 of the first sheet 51 , it will be understood that, immediately thereunder and facing in the same direction, will be the inside surface 59 of the second sheet 53 , which is shown in FIG. 14 . Thus, it can be seen that, when the 16 interfitting puzzle pieces 65 are removed, the second incomplete visage 77 will be exposed, coming into full view to the recipient. In its simplest form, the recipient of the laminated item will be directed to reassemble the 16 interfitting puzzle pieces 65 in appropriate alignment and orientation on the rectangular platform section 67 , which is located immediately below the second visage 77 that appears in the laminated item when the pieces 65 are removed. As previously indicated, the pressure-sensitive adhesive 71 that is used to laminate the two sheets preferentially adheres to the surfaces of the die-cut puzzle pieces because of the release coating that was applied to the areas of the first and second incomplete visages. The grid system imprinted in the platform region 67 assists the recipient in the alignment of the individual pieces and permits the recipient to complete the first puzzle by rearranging the adhesive-carrying pieces into proper orientation thereof in the platform region 67 on the outside surface of the first sheet so as to form a complete visage. Once the first puzzle is complete, the recipient would flip the item over 1800 so as to view the surface depicted in FIG. 15, i.e. the outside surface 61 of the second sheet 53 which is known to be laminated atop of the inside surface 57 of the sheet 51 , that is depicted in FIG. 13 . Thus, it will be understood that the first incomplete visage 69 lies immediately below the 16 die-cut puzzle pieces 75 . The recipient may then wish to invert the item head to foot so as to locate the puzzle pieces 75 in the upper region of the frame 73 and then remove those 16 puzzle pieces as done previously, exposing the incomplete first visage 69 . The pieces 75 that would then be reassembled, as explained hereinbefore, in the platform section 79 , which is also shown to have a printed grid to assist in proper alignment of the pieces, to complete the visage. It should be understood that completing an incomplete visage is only exemplary, and alternatively two complementary visages could be used, each of which might be complete in itself. As previously mentioned, if desired, the scrambled pieces could be printed with a small identifier on the front, or preferably on the rear surface thereof that could be seen through clear pressure-sensitive adhesive, which identifier would direct the recipient to which of the numbered boxes in the grid that particular puzzle piece should be placed and attached. In a promotional item, such assistance to the recipient might be felt to be warranted. On the other hand, if it were desired to make solution of the two puzzles even more difficult, the sheets 51 and 53 could be printed so that some of the puzzle pieces 65 together with some of the other pieces 75 would be required to complete the second visage, while the remainder would be used to complete the first visage. By such a double scrambling of the pieces, a recipient might need to first remove all 32 pieces and then carefully examine both the first and second incomplete visages in order to determine how all 32 puzzle pieces should be reassembled in order to solve both of the puzzles. Although the two puzzles are shown to be located vertically above and below each other, with the sheet being oriented with its longer dimension vertical, it should be understood that the die-cut puzzle pieces could instead be formed in either the right or left one-half of the region within the perimeter frame 63 , so as to create a long narrow platform upon which reassembly would occur either to the right or left of the region from which the pieces were removed. Depicted schematically in FIG. 16 is an alternative embodiment of a double puzzle arrangement 81 where the perimeter frame is eliminated by printing first and second sheets 83 , 85 so as to have a narrow central region 87 , 87 a extending across the sheet from edge to edge which narrow region would separate die-cut puzzle pieces 89 of the first sheet from a platform section 91 of the first sheet upon which these puzzle pieces might be reassembled as previously described. This narrow central region 87 of the first sheet would be aligned with a similar narrow central region 87 a of the second sheet. They could be held together in the lamination either by an overall coating of pressure-sensitive adhesive or by a strip of permanent adhesive that could be laid down in this region on one of the two sheets which would secure the two sheets 83 , 85 in a particularly stable condition. Except for the foregoing, the construction would be substantially the same as previously described. The narrow center region 87 could be simply left blank but would more appropriately be printed so as to simply continue the pattern of the visage 93 that will be uncovered by the removal of the puzzle pieces 89 , or in a situation where the reassembled puzzle pieces are not a continuation of the first visage but one that is complementary thereto, the narrow center region 87 could be split so that the lower half of it would be an extension of the graphic representation resulting from the proper reassembly of the 16 puzzle pieces. Once the lamination was complete, kiss-cutting would be effected so as to die-cut the puzzle pieces 89 in essentially one-half of the first sheet 83 and puzzle pieces 95 in essentially the other half of the second sheet 85 , with the die-cut pieces being printed in a scrambled orientation and being retained in such orientation by the pressure-sensitive adhesive that holds them to the first or second visage. The puzzles would be solved in the manner explained hereinbefore, and the item 81 bearing the two solved puzzles is depicted in FIG. 17 . Although the invention has only been described with regard to certain preferred embodiments, it should be understood that various changes and modifications as would be obvious to one having ordinary skill in this art may be made without deviating from the scope of the invention which is defined by the claims appended hereto. For example, the shapes of the puzzle pieces could be made much more complicated, employing shapes such as those found in the usual jigsaw puzzles and the like, for instance a pattern of five or six pieces might be repeated in two or three or more sections of the overall frame. The frame of course need not be square or rectangular but could be circular or have any desired shape so long as it is conducive to having groups of pieces of the same shape that can be scrambled while still filling the frame area. Instead of employing an overall coating of pressure-sensitive adhesive, a suitable pattern, e.g. striations, might be used. With respect to the promotional item 11 , two or more puzzles might be provided in different frame regions, and optionally, to increase the difficulty and enjoyment, the pieces from the two puzzles may be printed so that they are mixed with each other. Particular features of the invention are set forth in the claims that follow.
An assortment of two-sided puzzles are illustrated which are particularly suitable for use as promotional vehicles, postcards and game or novelty items. One embodiment employs a transparent backing sheet to which a set of puzzle pieces are attached by pressure-sensitive adhesive to one surface which set can be reassembled in a frame region to display a hidden promotional message. A postcard embodiment uses a similar transparent backing sheet to create a novelty piece wherein a plurality of interfitting pieces can be rearranged through the use of pressure-sensitive adhesive backings to either unscramble a message or uncover a scrambled visual pictorial. Another embodiment prints both sides of two sheets that are then laminated together via pressure-sensitive adhesive to create a lamination that contains a pair of puzzles that are solved through the use of a visage that only becomes exposed to view once a set of die-cut puzzle pieces is removed.
0
FIELD OF THE INVENTION This invention relates to camouflage worn by hunters, in more particularly to a readily attachable, detachable camouflage element which may be wrapped about the body of the hunter while effectively breaking up the outline of the hunter himself. BACKGROUND OF THE INVENTION Hunters are very cognizant of the effectiveness of using camouflage as a part of the hunter's apparel to prevent wild game such as wild turkeys, deer and the like from discerning the hunter. This is particularly true in the hunting of wild turkeys, since they have very keen eyesight. Since World War II, hunters have adopted military tactics of camouflaging the human body. In part, the camouflage involves using colors for the articles of apparel which match or blend with the surrounding terrain, trees, bushes and like vegetation. In changing from a unicolor fabric such as khaki, the cloth itself is given a camouflage effect by random, irregular color treatment in muted browns, greens, and the like to provide an effect known as "camouflage cloth". However, while such clothing had a positive effect in camouflaging the person wearing the same, since the cloth is in effect, "two dimensional", it did nothing to break up the outline of the person wearing such clothing. It is therefore an object of the present invention to provide a body wrap strip having physically affixed to the strip over the length of the same, artificial leaves, flowers, weeds, etc. which strip, when wrapped about the body, creates a three-dimensional camouflage effect, which readily blends to the muted greens and browns of the clothing worn by the hunter, which may readily and quickly wrapped about the body of the hunter, which does not inhibit movement by the hunter, and which materially increases the difficulty of the game being hunted for discerning the hunter wearing such camouflage strips. SUMMARY OF THE INVENTION The invention constitutes a camouflage wrapping strip for random body wrapping about the body of the hunter and consists of a given length of strip material. Mutually engageable fasteners are at longitudinally spaced positions along the length of the strip permitting the strip to be a snap attached to itself at crossing points of the strip when wrapped about the body of the hunter. A plurality of artificial foliage elements are fastened to the strip at longitudinally spaced positions, whereby, the strip may be wrapped about the body of the hunter, snapped together at crossover areas to loosely lock the strip to the body such that the fauna elements carried thereby effectively breaks up the body outline. The artificial foliage elements may constitute artificial flowers, leaves, weeds, etc. The flexible strip may be of cloth, plastic or wire. The fasteners may comprise engageable male and female metal or plastic, snap fasteners, or hook and loop type patches fixed to opposite faces of the thin flexible strip of material, randomly or at uniformly spaced locations. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an outdoorsman, wearing the body wrap camouflage strip forming a preferred embodiment of the invention. FIG. 2 is an enlarged, plan view of the strip of the body wrap camouflage strip of FIG. 1 showing alternate modes of attachment of artificial leaves to the strip at various locations. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 1 and 2, the present invention is directed to a body wrap camouflage strip indicated generally at 10 which is worn by an outdoorsman such as a hunter, indicated generally at 12, with the strip wrapped about the arms, shoulders, torso and legs of the hunter. The showing in FIG. 1 is exemplary only of the nature of the wrapping. The body wrap camouflage strip is readily placed on and wrapped about the body of the hunter and snap fitted together at areas of strip crossover so as to be maintained in place. The strip may be attached after the hunter has found a location i.e. at the "hunters stand" although, the body wrapping of the strip and the attachment to itself may be such that the hunter 12 is permitted to move with the body wrap camouflage strip attached to the exterior. Strip 10 is wrapped about the body of the hunter 12, for instance, by starting at one end of the body wrap camouflage strip 10. As shown, initial attachment and wrapping occurs about one of the arms 18, extends over the shoulder and behind the head 22 of the hunter, along the other arm 18, short of the hand 20, back about the torso 14. The wrapping is completed along a leg 16. The body wrap camouflage strip attaches by being connected back to itself at longitudinally spaced crossover locations. In that respect, the body wrap camouflage strip 10 is comprised of a given length of strip material 24 which may be a woven cloth, a plastic film, a wire or the like. At a longitudinally spaced, preferably random location, the strip material 24 has fixed thereto, artificial flowers 34, leaves 30, ferns 32, flowers 34, and short length tree or bush limbs 36, FIG. 1. The manner of attachment of such artificial flowers, leaves, weeds, limbs, ferns and like artificial foliage elements, may be seen by reference to FIG. 2. In this case, a series of artificial leaves 30 patterned after the common oak leaf, are shown as attached to the strip material 24. Starting to the left and moving to the right, the leaves 30 may be sewn as indicated by stitching 38, may be glued at 40; or may be attached by wire staples or the like 42. Alternatively, each artificial leaf 30 or similar artificial foliage element may have as an element thereof, a metal or plastic snap 44 mating with a further metal or plastic snap 46 which is fixedly mounted to the face of the strip material 24. Further, an artificial leaf, or leaves 30 may be attached as a unit, as shown to the right, FIG. 2, by means of one patch of a hook and loop mating fastener of the type sold under the registered trademark VELCRO. Shown to the right in FIG. 2, a patch 48 is physically connected to two leaves 30 and bears a large number of hooks 50 on the surface thereof which mate with the exposed face of a matching patch 52 bearing loops 54. A coupling is achieved as indicated by the arrows for the metal or plastic snaps 44,46 and the mating VELCRO fastener patches 48,52. The body wrap camouflage strip 10 takes the appearance of a natural vine. The leaves, flowers, ferns, limbs, weeds, etc. may be constructed from various materials such as cloth, plastic or paper and are appropriately colored. The body wrap camouflage strip may have all of the same type flowers, leaves, etc., or it may have a combination of flowers, leaves, weeds, ferns, etc., of various sizes, depending on the type of camouflage effect desired. However, in all cases, the effect by attaching one or more of the body wrap camouflage strips 10 to the body of the hunger 12 is to create a three-dimensional effect and to break up the outline of the hunter. The leaves and flowers may be of a single color or they may be of one color on one side and a different color on the opposite side. Even where they are of the same color, one side may be lighter than the other. The leaves and flowers may be of different size, some large and some small, and attached at different length intervals along the strip material 24. While the body wrap camouflage strip 10 as shown in FIG. 10, starts at one arm and terminates at the bottom of the leg, by the presence of the mateable metal or plastic snaps 28,26, alternative attaching or snap coupling devices may be mounted to the strip material 24 at random locations over the length of the same. As a result, the body wrap camouflage strip 10 or a series of such strips will equip a person with a fast, easy and efficient type of camouflage. The product is especially useful to outdoorsmen such as bird watchers, hunters or other persons who need to be in an outdoor environment without being detected. The body wrap camouflage strip 10 may have military application. Additionally, the articles of clothing such as a shirt 56 or slacks 58 of hunter 12 may carry mateable snaps 26,28 as shown in FIG. 1 (or VELCRO patches) at different locations to permit the strip material 24 to be attached and snap fitted thereto or to cling thereto as with the VELCRO fasteners. While an illustrated preferred embodiment has been described, those skilled in the art will recognize the superior changes in the disclosed structure may be made without departing from the spirit and scope of the invention.
A camouflage wrapping strip that takes the form of a given length of strip material such as cloth, plastic or the like having mutually engageable fasteners at longitudinally spaced positions over the length of the strip for overlapping attachment across the points of the strip when wrapped about the body of a hunter. Artificial foliage elements are fastened to the strip at longitudinally spaced positions with the foliage elements breaking up the body outline. The artificial foliage elements may be artificial flowers, leaves, weeds, etc.
8
FIELD OF THE INVENTION The present invention relates to a tool for gaining access to a locked motor vehicle, for example engaging the lock button of the vehicle door. BACKGROUND OF THE INVENTION It is not uncommon that the owner or operator of a motor vehicle lock the doors of the motor vehicle for example with the key left in the ignition switch. This leaves the owner or operator with the problem of opening the vehicle without damaging it. Professional motorist assistance services exist and may be brought in to solve the problem, but this may cause an objectionable delay and may incur costs. In past years owners have resorted to attempting to manually open doors if a vehicle window has been left slightly open, or by maneuvering a wire tool past the weather gasket of the door. A wire tool may be fashioned from commonly available materials such as coat hangers for example. However, in an effort to dissuade theft, vehicle manufacturers have attempted to make it more difficult to gain access to the vehicle by such measures. One of the steps many manufacturers have adopted is to eliminate or minimize the enlarged head which in past years characterized door lock buttons. While access through the window to the door lock button and to the door handle remain among the most practical ways to engage a door lock button, current vehicle manufacturing practice now requires tools more adapted to this purpose than was formerly the case. SUMMARY OF THE INVENTION The present invention provides an access tool which is well suited for the task of engaging a modern door lock button to open a door of a motor vehicle. The novel tool has a long slender shaft which is sufficiently flexible as to yield to obstacles as it is maneuvered into place, yet which is sufficiently rigid as to be guided while being grasped at one end while causing a snaring loop at the opposite end to be maneuvered over the shaft of a vehicle door lock button. The novel access tool may have an internal stranded metallic cable which is capable of resisting significant manual pulling forces to accommodate opening of the vehicle door lock button. One aspect of the invention is that it is modular in that it comprises a plurality of mutually attachable and removable components. Connections are unthreaded, for example being friction fit and locked by a detent device which does not require threading. A pin may be inserted through the long, slender body of the tool to lock two body sections together. The novel access tool may have a variety of replaceable working heads each adapted for a particular task. For example, the tool may have a flexible loop for engaging a door handle, a rigid hook, a magnet, and a miniature flash light. It is an object of the invention to provide a modular access tool for gaining access to locked motor vehicles. Another object of the invention is to eliminate tedious threading of modular sections together. It is an object of the invention to provide improved elements and arrangements thereof by apparatus for the purposes described which is inexpensive, dependable, and fully effective in accomplishing its intended purposes. These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings. BRIEF DESCRIPTION OF THE DRAWINGS Various objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: FIG. 1 is a plan view of a kit of components which may be assembled to form an access tool according to at least one aspect of the invention. FIG. 2 is an environmental plan view of an exemplary access tool assembled from the kit of FIG. 1 in a configuration adapted to engage a door lever of a motor vehicle. FIG. 3 is a plan view of a component bearing a loop for engaging a door handle of a motor vehicle. FIG. 4 is a plan view of an alternative component bearing a loop for engaging a door handle of a motor vehicle. FIG. 5 is a side view of the component of FIG. 4 . FIG. 6 is a side view, shown partially in cross section, of a working head for holding a magnet. FIG. 7 is a cross sectional side view of a connector sleeve. FIG. 8 is a side cross sectional view of an alternative working head for holding a magnet. FIG. 9 is a side view, shown partially in cross section, of still another holder for a magnet. FIG. 10 is a top view of a connector. FIG. 11 is a side view of the connector of FIG. 10 . FIG. 12 is an end view of the connector of FIG. 10 . DETAILED DESCRIPTION Referring first to FIGS. 1 and 2 , according to at least one aspect of the invention, there is shown a kit 10 of components of the modular access tool of the present invention. The tool is modular in that firstly, it may be assembled by joining selected ones of the components depicted in FIG. 1 to form a tool having characteristics for performing one of several optional ways of engaging the door handle (see FIG. 2 ) or a door lock button (not shown) of a motor vehicle (a portion of which is shown in FIG. 2 ). Secondly, the access tool may include different components so that it takes slightly different forms according to which of the selected ones of the components have been assembled. The access tool may vary in overall length, in the type of working head assembled thereto, or in both ways. Therefore, it must be understood that any one access tool assembled from the components of the kit 10 may leave one or more components unused in any one application. FIG. 2 shows an exemplary assembly of an access tool 100 of the present invention. The access tool 100 may comprise a main body section 102 , an extension 104 , and a working head 106 bearing a loop 108 . In FIG. 2 , the loop 108 is depicted snaring a door handle 2 . Pulling by hand on the tool 100 will cause the door handle 2 to swing as indicated by the arrow A, thus opening the door. It will be appreciated that the tool 100 has been slipped into the interior of the vehicle, or the cabin, by pushing it past door and body gaskets (not shown) of the vehicle body. The components of the tool 100 are sufficiently slender as to pass through such a space. Some vehicles may have door levers configured so as to be better engaged by a hook such as the hook 110 formed on a component 112 comprising a main arm section 114 which accounts for most of the length of the component 112 , the hook 110 , and an angled section 116 which may be snap fit or otherwise removably connected to the main body section 102 . It will be seen in FIG. 1 that the angled section 116 may form an angle (indicated by an arrow B) of about one hundred thirty-five degrees with the main arm section 114 . The hook 110 may be formed by straight sections 118 , 120 arranged at an included angle (indicated by an arrow C) defined between the straight sections 118 , 120 of about one hundred thirty-five degrees. The straight section 118 may be arranged at an included angle (indicated by an arrow D) defined between the straight section 118 and the main arm section 114 of about one hundred thirty-five degrees. The main body section 102 may also have an included angle (indicated by an arrow E) defined between a principal section 122 and a relatively short transition section 124 of about one hundred thirty-five degrees. The main body section 102 may include a handle 125 having a diameter 127 defined along its length which is greater in magnitude than the diameter 129 of the main body section 102 . It will also be appreciated that the diameter 129 of the main body section 102 is substantially similar to the diameter 131 of the extension 104 . Preferably, comparable diameters of other extensions where provided, are similar to the diameter 129 . Other access tools (not shown) may be formed by incorporating additional extensions such as an extension 126 bearing the hook 110 , an extension 128 bearing an illumination lamp 130 , or a working head 132 incorporating a magnet 134 . An illumination lamp may be formed in the dimensions and proportions of a working head such as the working head 132 if desired. Where provided, the illumination lamp may include an electrical power source such as a battery cell (not separately shown) and if desired, an externally accessible switch adapted to switch the illumination lamp on and off. FIG. 3 shows details of the working head 106 . The working head 106 may comprise the loop 108 and a base 136 . The loop 108 may comprise metallic strands, which may be retained within flexible sleeves 138 , 140 . The free ends 142 , 144 of the loop 108 may be secured by crimping the base 136 thereover. The base 136 may have a socket 146 formed therein for attachment to an elongated component of the kit 10 , such as the component 112 , or an extension such as the extension 104 . FIGS. 4 and 5 show an alternative working head 150 which may comprise a loop 152 and a base 154 which entraps and retains the loop 152 by being crimped thereover for example. The loop 152 may comprise metallic strands retained and organized by sleeves 156 , 158 . The working head 150 may engage another component of the kit 10 other than by a socket such as the socket 146 of FIG. 3 . Instead, the working head 150 may incorporate a mechanical detent device such as a pin 160 . The pin 160 may engage a socket 162 by friction for example. Other mechanical detent devices may be provided in place of the pin 160 . For example, a device wherein a projecting member is spring urged to engage and project outwardly from an opening such as the socket 162 , which may be pressed manually out of interference with a sleeve or other member to release engagement may be provided. This is a well known type of detent device and need not be further described herein. It is merely desirable to note that connection of elongated members such as the component 112 to an extension such as the extension 104 is preferably provided by a detent device which does not rely on screw threading, so that elongated members may be rapidly pressed together and separated when desired. FIG. 6 shows a light tip extension 164 . The light tip extension may have a socket 166 for connection to an elongated member and a socket 168 for receiving a pin or other mechanical detent device (neither shown). FIG. 7 shows a connection arrangement which may be employed to connect elongated members such as the component 112 , extensions such as the extension 104 , and working heads such as the working head 106 if desired. In this arrangement, a sleeve 170 forms a female member into which may be inserted a male member such as an end terminal 172 . The end terminal may have a throughbore 174 which may be aligned with holes 176 , 178 formed in the sleeve 170 to receive a mechanical detent device such as a pin (not shown). The sleeve 170 may have an aditional hole 180 which may receive a complementing end terminal (not shown, but which may be similar to the end terminal 172 ), so that two end terminals may be retained within the sleeve 170 by pins. It will be appreciated that the end terminal 172 has a tongue 182 which occupies half of the open interior space of the sleeve 170 . This accommodates a corresponding tongue of the complementing end terminal in close cooperation therewith. That is, a complementing tongue may occupy that portion of the sleeve 170 which is left unoccupied by the tongue 182 , where the complementing tongues overlap one another for a portion of the length of the sleeve 170 . The working head 132 is shown in detail in FIG. 8 . The magnet 134 is seen received within a socket 184 which faces in one direction, with an oppositely opening socket 186 facing an opposite direction. The sockets 184 , 186 may be separated by an internal flange 188 which limits penetration of the magnet 134 into the socket 184 and by an elongated member such as the component 112 or an extension such as the extension 104 into the other socket 186 . As seen in FIG. 9 , a magnet (not shown) may be retained within a working head 190 . The working head 190 may comprise a socket 192 which may be crimped over the magnet, and an engagement end 194 comprising a socket 196 and a tongue 198 which is structurally and functionally similar to the tongue 182 of FIG. 7 . FIGS. 10 , 11 , and 12 show an adaptor 200 which may be employed to join elongated members such as the component 112 , extensions such as the extension 104 , and working heads such as the working head 106 if desired. The adaptor 200 may comprise a tongue 202 , a socket 204 , and an outwardly projecting low wall 206 which limits penetration of the adaptor 200 into an elongated member or working head by interference fit. While the present invention has been described in connection with what is considered the most practical and preferred embodiment, it is to be understood that the present invention is not to be limited to the disclosed arrangements, but is intended to cover various arrangements which are included within the spirit and scope of the broadest possible interpretation of the appended claims so as to encompass all modifications and equivalent arrangements which are possible.
A modular access tool for operating door handles and door locks of motor vehicles from the exterior of the motor vehicle. The access tool is provided in sections which are removably attachable to one another such that the overall operative length is adjustable in discrete steps. A working head, such as a loop, a hook, or a magnet is attachable at the end of the access tool. Optionally, an illumination light may be attachable at the end of the access tool. Sections join together by threadless interference based detent devices.
4
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to an improved apparatus and process for taking up textured yarn plugs into a cartridge. More particularly, this invention relates to an improved apparatus and process for taking up textured yarn plugs in an orderly arrangement, such that the yarn can be removed thereafter without entanglement. 2. Description of the Prior Art In a high-speed texturizing process, high-speed winders are required to take up the textured yarns. These winders are relatively expensive, are of questionable reliability, and are extremely noisy. Therefore, an alternative to these high-speed winders is desirable. Accumulating yarn in plug form is known in the prior art; for example, in U.S. Pat. No. 3,172,185 of Mar. 9, 1965 to Langway and Billings; U.S. Pat. No. 3,316,609 of May 2, 1967 to C. J. Russo; U.S. Pat. No. 3,341,911 of Sept. 19, 1967 to J. W. Smith and U.S. Pat. No. 3,441,989 of May 6, 1969 to R. G. Clarkson et al. Each of these prior art patents suffers from one or more of the following disadvantages: complex equipment is needed to convey the yarn plug into the receiver; the packaging equipment must be tailored to accommodate a particular texturizing apparatus; and since all the yarn is deposited into a single receiving chamber, there is a tendency for the yarn to become tangled on removal. U.S. Pat. No. 3,058,690 of Oct. 16, 1962 to Russo et al. and U.S. Pat. No. 3,980,176 to B. A. Boggs disclose a plug storage apparatus which requires the plugs to be wrapped in a plastic tape, forming a sausagelike tube. After the yarn is removed, the wrap must either be discarded or rewound for reuse, which procedures are complex and inconvenient. 3. Summary of the Invention One object of this invention is to provide a cartridge takeup apparatus as a replacement for costly high speed winders. Another object of this invention is to provide a takeup apparatus which can operate at yarn speeds for which high speed winders are unavailable (i.e., speed >6000 m per minute). Another object of this invention is to provide a yarn plug takeup apparatus from which the yarn can be removed without entanglement, as well as a process for removal of the yarn. In accordance with the present invention, an improved takeup apparatus for packaging yarn plugs comprises a spiral-walled cartridge for receiving yarn plugs from a yarn texturizer; a support for the base of said cartridge, said support having a spiral wall extending downward, the shape of said wall corresponding substantially to the shape of said cartridge wall; a shaft upon which said support is mounted; means for driving said support around said shaft by contacting the spiral wall of said support with a driving means; means for applying a lateral force to said shaft to hold the spiral wall of said support in non-slip contact with said driving means; means for sensing the lateral position of said support; and means for changing reversibly the direction of said lateral force such that the contact point of the driving means shifts from a point on the inside of the support spiral wall to a point on the outside of the wall. In operation, the process comprises placing a cartridge having a spiral storage area beneath the texturizer outlet; causing the yarn plugs to fall along one side of the spiral storage area by rotating said cartridge in one direction (e.g., counterclockwise) at a speed substantially equal to that of said yarn plugs; sensing the lateral position of said cartridge at a point where continued rotation would cause said yarn plugs to fall at one extreme (e.g., innermost) section of the storage area in about 0.01 to 1 second; laterally shifting said cartridge to cause said yarn plugs to fall along the opposite side of said storage area by rotating said cartridge in the opposite direction (e.g., clockwise) at a speed substantially equal to that of said yarn plugs; sensing the lateral position of said cartridge at a point where continued rotation would cause yarn plugs to fall at the other extreme (e.g., outermost) section of the storage area in about 0.01 to 1 second; laterally shifting said cartridge to cause it to rotate in the original direction; continuously feeding yarn plugs into said cartridge by causing it repeatedly to rotate in one direction, shift, rotate in the opposite direction and shift; and removing said plug-containing cartridge from beneath the texturizer outlet. Since the plugs typically travel at about 1% of the yarn speed, the plug takeup can operate at a low speed, permitting simple design and low cost. The invention does not require a specially designed texturizer for its operation, and there is no need to wrap the yarn plugs. After plugs have been deposited in a cartridge, the cartridge may be removed from the apparatus. The yarn plugs may then be pulled out over a tension gate, wound on a beam and later on knitted or weaved into fabric. Of course, many tens or hundreds of cartridges (i.e. yarn ends) may be required for the beaming operation. Alternatively, the cartridge may be used to feed a knitter directly. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood and additional advantages will become apparent when reference is made to the following description and accompanying drawings in which: FIG. 1 is a vertical section of the preferred cartridge takeup apparatus of this invention. FIGS. 2a, b, c and d are each a horizontal section taken along the line 2--2 of FIG. 1 and show the rotor and support wall positions at successive time periods of the takeup cycle. FIG. 3 is a fragmentary vertical section through a diameter of a partially filled cartridge. FIG. 4 is a top view of a filled cartridge and yarn take-off. FIG. 5 is a side view of the cartridge and yarn take-off. FIG. 6 is a top view of an alternative embodiment of this invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings in more detail, FIG. 1 shows a vertical section of the preferred embodiment of this invention. The textured yarn plug 10 emerges from a texturizer outlet 11 and impinges on the floor 12 of a section of a spiral groove of a cartridge 15, said groove formed by spiral wall 14. It is important that the yarn plug first contact the floor of the cartridge rather than the wall. If it first touches the wall surface, the wall friction slows down the plug and causes pilling up in random fashion. This results in severe entanglement during unwinding in a later stage. Cartridge 15 is fastened to support 16 and shaft 17 by a nut 18 on the threaded end of the shaft. Support 16 has an inverted spiral wall 19, the shape of said wall corresponding substantially to the shape of said cartridge wall 14. Bearings 20 and 21 prevent tilting of shaft 17. Rotor drive 24, retained by bearings 22 and 23 and driven by constant speed motor 25, rotates about a vertical axis, which passes through or near the center of texturizer outlet 11. During operation, texturizer outlet 11 and the axis of rotor drive 24 both remain fixed in space. Rotor drive 24 is in intimate contact with the wall 19 of support 16 to substantially prevent slipping. A piston 26 is powered by air or other compressible fluid in section 27 of cyclinder 28. The piston maintains intimate contact between rotor drive 24 and support wall 19 by exerting a lateral force through rod 29 and shaft 17. Shaft 17 slides in slots 30 and 31. Motor 25 drives support 16 at a constant speed, which is chosen to equal the speed of plug 10 as it impinges on the floor 12 of the cartridge groove. The plug speed is preferably about 1-1000 m per min, corresponding to yarn speeds up to about 10,000 m per min or more. The position of rotor drive 24 near the outer edge of spiral groove 32 is shown in FIG. 2a. As the rotor drive rotates in a clockwise fashion, the support rotates counterclockwise and moves laterally to the left under the force of piston 26. FIG. 2b shows the position of support 16 at a later time, when it has been pushed to the left a distance twice the sum of groove plus wall width. FIG. 2c depicts the position of support 16 when the extreme inner section of wall 33 of spiral groove 32 has reached the rotor drive. At that point, sensor 34 activates solenoid-controlled 4-way valve 35 which switches the air flow to section 36 of cylinder 28. Piston 26 moves to the right, driving the takeup to the right and causing rotor drive 24 to come into contact with the opposite section of wall 37 (dashed line) of spiral groove 32. Thence, the continued clockwise rotation of rotor drive 24 drives the takeup clockwise. FIG. 2d depicts the position of support 16 when the extreme outer section of wall 38 has reached the rotor drive. Sensor 34 activates solenoid-controlled 4-way valve 35, which switches the air flow back into section 27 of cylinder 28. Piston 26 moves to the left, driving the takeup to the left and causing the opposite section of wall 39 to come into contact with rotor drive 24. The takeup is driven counterclockwise, and the sequence depicted in FIGS. 2a,b,c, and d repeats. In the preferred embodiment, sensor 34 is a magnetic relay switch which detects the position of piston 26 and activates a solenoid-controlled 4-way valve 35. A person skilled in the art will recognize that other sensing means, e.g., mechanical or photo detectors, could serve in place of the magnetic sensor. The yarn plugs may be composed of any suitable filamentary material including material chosen from the group consisting of poly 1,4-cyclohexylenedimethylene terephthalate, polyethylene terephthalate, polyhexamethylene adipamide, poly ε-aminocaproic acid, polypropylene, cellulose acetate, cellulose triacetate and glass. The plug density is preferably in a range from 5% to 75%, where plug density is defined as the ratio of the weight per unit volume of plug to the weight per unit volume of solid filamentary material. The plug cross-section may be substantially round, rectangular, or square, with plug size ranging from about 0.05 cm to 8.0 cm on a side or the equivalent. FIG. 3 shows the arrangement of the yarn plugs in the cartridge. To achieve this arrangement of plugs, the rotor drive diameter must be less than half the groove width. Section "A" is deposited during the counterclockwise rotation of the cartridge as depicted in FIGS. 2a and 2b. Section "B" is deposited during the interval between FIG. 2c and 2d. During the following cycle, sections "C" and "D" are deposited in that order. When sufficient yarn plugs have been deposited, the cartridge 15 may be removed from the apparatus by removing nut 18 and replaced with an empty cartridge. The cartridge, functioning similarly to a conventional bobbin, should be relatively low cost. FIG. 4 shows cartridge 15 containing plugs 10 and being unwound through an arm 46 having a slit 40. The arm is mounted on low-friction bearings 41 which rotate freely as the textured yarn is pulled out through the slit. Arm rotation is alternately clockwise and counterclockwise, with rotation direction reversing when yarn is being withdrawn from the outer and inner sections of groove 32. FIG. 5 shows textured yarn 42 being pulled from cartridge 15 through the slit in arm 46 and through pigtail 43. Thence the yarn goes over a tension gate and may either be wound on a beam or go directly to a knitter. Alternatively, as shown in FIG. 6, the plug-containing cartridge may be covered with a closure (cap) 44. The cap has a spiral slit 45 so positioned that when cap 44 is on cartridge 15, slit 45 is located substantially over the center of the spiral groove in cartridge 15. The yarn 10 may be unwound through slit 45 in cap 44 without using arm 46. The following example is presented in order to provide a more complete understanding of the invention. The specific techniques, conditions, materials and reported data set forth to illustrate the principles and practice of the invention are exemplary and should not be construed as limiting the scope of the invention. EXAMPLE The cartridge of FIG. 1 comprised a base of polycarbonate board, 30.5 cm diameter×0.64 cm thick, on which was glued a spiral wall of polycarbonate sheet, 6.4 cm high×0.13 cm thick×178 cm long, with a pitch of 1.9 cm. The support comprised a spiral wall of low carbon steel, 1.3 cm high×0.05 cm thick×178 cm long with a pitch of 1.9 cm glued on a base of polycarbonate board, 30.5 cm diameter×0.64 cm thick. The flat surfaces of the cartridge and support bases were bolted together. A double action air cylinder under pressure of about 700 dynes/cm 2 acting through the piston rod pushed the spiral wall of the support against a rotor to cause frictional drive. The rotor had a diameter of 1.3 cm and had a thin rubber strip wrapped around it. The rotor rotated clockwise at a substantially constant rate of about 290 rpm, yielding a cartridge speed of 12 m per min. The yarn used was nylon 6, 35 denier/12 filaments. If was formed by the yarn texturizer into square plugs about 0.14 cm on a side and having a density of about 15%. The texturing speed was about 1,000 m per min. and the plug speed about 12 m per min. Referring to FIG. 2a, the yarn plug deposition began with the rotor drive near the outer edge of spiral groove 32. The rotor drove the spiral wall surface in a counterclockwise direction, the plugs deposited during this period being shown as section "A" in FIG. 3. During the period, the support was driven laterally by the piston a distance of 2.8 cm, the travel preset by positioning the magnetic sensors. A magnetic sensor then activated a solenoid-controlled 4-way valve. The support was thus shifted laterally and the rotor drive contact point also shifted from the outside of the spiral wall to the inside. Then, while the rotor still rotated clockwise, the spiral wall also was driven clockwise. During clockwise rotation, plugs were deposited (section "B" in FIG. 3) in the groove alongside the plugs deposited (section "A" in FIG. 3) during counterclockwise rotation. After the clockwise rotation of the spiral had brought the rotor into contact with the outer section of the wall as shown in FIG. 2d, the solenoid valve was again activated, the takeup shifted and the cycle repeated until the groove was filled with 50 g of plugs. The cartridge was removed from the apparatus and the textured yarn removed through a slit in a rotating arm as shown in FIGS. 4 and 5. The yarn was wound on a bobbin at 500 m per min. The yarn was knitted on a Lawson-Hemphill Fiber Analysis Knitter having a 54 gauge head, 220 needles, a diameter of 8.9 cm and 91 cm per course. The knitted fabric, when dyed, showed good texture and uniformity.
An improved apparatus for taking up textured yarn plugs into a cartridge is provided. The apparatus comprises a spiral-walled cartridge and means for rotating the cartridge about a vertical axis while moving it laterally. In operation, the cartridge is rotated beneath a yarn texturizer as textured yarn in plug form is deposited therein in orderly layers. Even with high-speed texturizers, cartridge speed is low. After the plugs have been deposited, the cartridge may be removed, and the yarn plugs may be pulled out for knitting or weaving.
1
FIELD OF THE INVENTION This invention relates generally to electrical circuit breakers and more particularly to such interrupters used as aircraft circuit breakers. BACKGROUND OF THE INVENTION It is conventional for aircraft circuit breakers to have an overload responsive member such as a current carrying bimetal, typically called a bimetal trip arm, which has a portion which deflects with changes in temperature to move a slidably mounted connecting plate which is adapted to engage and displace a trip arm. One part of a latch mechanism is movable with the trip arm and upon occurrence of an overload the one part of the latch mechanism is separated from a catch portion which allows a collapsible linkage mechanism to move a movable contact into an open contacts position. Such a device is shown, by way of example, in U.S. Pat. Nos. 4,827,233 and 4,837,545, assigned to the assignee of the present invention, the disclosure of which is included a herein by this reference. Typically a high localized contact force exists between the interengaging surfaces of the latch and its catch. Such surfaces are manufactured so that they are extremely smooth and wear resistant, using expensive materials thereby increasing component costs. Although such devices are effective, the friction of the latching mechanism tends to change over time introducing variability and can eventually change the calibration of the circuit breaker. Additionally, such devices require a relatively large number of components, particularly in multiphase breakers where several contact, linkage and latch mechanisms are ganged together. SUMMARY OF THE INVENTION It is an object of the invention to provide circuit breaker free of the prior art limitations noted above. Another object of the invention is the provision of an electrical circuit breaker which performs the same functions as conventional aircraft circuit breakers yet has no latch mechanism with concomitant friction. Yet another object of the invention is to provide an electrical circuit breaker which is trip free, can be made for use with single phase or multiphase applications and which has fewer parts and less weight than prior art devices. Briefly, an electrical circuit breaker made in accordance with the invention comprises a housing in which a stationary electrical contact and a movable contact mechanism having a movable electrical contact are mounted with the movable electrical contact being movable between contacts open and closed positions. The movable contact mechanism is pivotably mounted and is provided with a first spring member urging the movable contact mechanism toward the open contacts position. A push-button is mounted on the housing and is connected to one end of a plurality of end to end interjointed link members with the opposite end connected to the movable contact mechanism. The first link is rotatably connected to the housing at a location intermediate to the first and second ends of the link. One end of the first link is formed with a slot to receive therethrough a pin of the push-button for converting linear motion of the push-button to rotary motion of the first link. The second end of the first link forms a first movable over center joint and is pivotably connected to the first end of a second link. The second end of the second link forms a second movable over center joint and is in turn pivotably jointed to the first end of a third link whose second end is pivotably connected to the movable contact mechanism. A stop surface is disposed on one side of, and closely adjacent to, a first imaginary straight line extending through the rotational connection of the first link to the housing and the second movable over center joint and a second imaginary straight line extending through the first movable over center joint and the pivotable connection of the second end of the third link. A second spring member biases the second movable over center joint toward the stop surface and when the push-button is depressed the first link is rotated against the bias of the first spring member moving the movable contact mechanism toward the contacts closed position with the first movable over center joint moving over center across the first imaginary line and into engagement with the stop surface essentially straightening out the several links and moving the movable contact mechanism into the closed contacts position. An overload responsive trip member in the form of a current carrying bimetal trip arm is caused to deflect upon a selected overload current which deflection is transferred to a rotatably mounted ambient bimetal compensator. Rotation of the bimetal compensator transfers motion through a motion transfer portion of the bimetal compensator to the second movable over center joint moving it over center to the other side of the second imaginary line thereby allowing the first spring member acting on the movable contact mechanism to open the contacts. As long as the overload bimetal member is in the overload deflected position the circuit breaker can not be reset even with the push-button held in the depressed position. According to a feature of the invention, the second movable over center joint is provided with a roller engageable with the stop surface to avoid sliding motion. According to another feature, the movable contact mechanism is preferably formed to provide a preload to obtain a desired level of contact force as by bending a spring member into a generally J-shaped configuration, mounting the movable electrical contact on a stiffened distal free end of the long leg and forming a lost motion pin connection between an intermediate location of the long leg and the distal end portion of the short leg of the J-shaped configuration. The movable contact mechanism is pivotably mounted to the housing adjacent the bight portion between the two legs so that when the third link transfers motion to the contact mechanism and closes the contacts, the pin rides in the slot with the spring member supplying the contact force. According to yet another feature, multiphase circuit breakers made in accordance with the invention have adjacent phase mechanisms which include corresponding contact mechanisms, overload responsive members and motion transfer connecting plates along with an arm of the ambient bimetal compensator but do not include additional toggle mechanisms thereby resulting in a decreased part count and device weight. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention and together with the description, serve to explain the objects, advantages and principles of the invention. In the drawings, FIG. 1 is a perspective view of a three phase circuit breaker made in accordance with the invention; FIGS. 2 and 3 are front and rear elevational views of the FIG. 1 breaker shown with the housing broken away for purposes of illustration; FIG. 4 is a side elevational view of the center phase of the FIG. 1 breaker shown without the front wall for purposes of illustration and shown with the push-button depressed and in the overload actuated, contacts open, trip free position; FIG. 5 is a view similar to FIG. 4 but shown in the contacts closed position; FIG. 6 is a view similar to FIG. 5 but showing an outer phase of a multiphase, ganged circuit breaker and shown with the push-button of the center phase; and FIGS. 7-9 are broken away, somewhat simplified side elevational views showing the toggle mechanism in the open, cooled condition (FIG. 7 ), closed contacts position (FIG. 8) and open trip-free position with the push-button depressed (FIG. 9 ). DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Although the drawings show a three phase circuit breaker, breakers made in accordance with the invention can be of a single phase version having only the phase identified herein as the center phase, i.e., as shown in FIGS. 4 and 5, for example, or can be of the version for multiphase applications in which several phases are ganged together as shown in FIGS. 1-3, for example. In either case, an electrical circuit interrupter 10 made in accordance with a first embodiment of the invention comprises a housing 12 having a top wall 12 a formed with an aperture 12 b for receipt of a bushing 14 and a push-button 16 . Push-button 16 is linearly movable between inner and outer positions as shown respectively in FIGS. 8 and 7. A push-button return spring 16 a (see FIG. 4) is mounted within bushing 14 and places a force on the push-button toward the outer position. The bottom portion of the push-button is provided with a pin 16 b which extends between spaced apart side portions 16 c (one side portion being shown) for connection with one end of a toggle mechanism 18 . Toggle mechanism 18 has a plurality of links 20 , 22 and 24 jointed together in end to end fashion to form a chain. First link 20 has first and second ends 20 a , 20 b and is rotatably connected to side wall 12 c of the housing by pin 20 c . Pin 16 b is received through a slot 20 d adjacent end 20 a of the first link, the slot preferably having a wider end furthest from the rotational connection to facilitate transition between linear motion of the push-button and rotational movement of link 20 . Link 20 is generally L-shaped with the rotational connection offset from a straight line joining ends 20 a , 20 b . It should be understood that other configurations for the link can be employed as long as the actuating force, push-button 16 in the embodiment shown, acts in a direction which is not in line with the rotational connection of the link with the housing. The second end 20 b of first link 20 is pivotably connected at 20 b to the first end 22 a of second link 22 and forms a first movable over center joint 3 . Second link 22 preferably is formed as a pair of overlying links members received on either side of first link 20 to allow uninhibited pivotal motion between the first and second link. The second ends 22 b of second link members 22 receive therebetween and are pivotably connected to the first end 24 a of third link 24 and form a second movable over center joint 4 . Preferably, freely rotatable rollers 26 are mounted at the pivotable connection at ends 22 b at movable joint 4 for rolling engagement with a stop surface 28 to be discussed. The second end 24 b of third link 24 is pivotably connected to a movable contact mechanism 30 . Movable contact mechanism 30 is pivotably connected to housing 12 at one end of the mechanism by pin 30 h . Movable electrical contact 30 a is movable into and out of electrical engagement with a stationary electrical contact 32 a between respective contacts closed and open positions. Preferably, movable electrical contact 30 a is provided with a preload as by forming the movable contact arm 30 b out of a strip of suitable spring material and bending the strip back over itself to form a generally J-shaped configuration having two legs extending from a bight portion with one end on the upper, shorter leg formed with two spaced apart, downwardly extending legs 30 c formed with pin receiving aperture 30 d and two spaced apart, upwardly (after bending) extending legs 30 e on the lower, longer leg having a generally vertically extending pin receiving slot 30 f formed in each leg. The legs extending from the bight portion are rigidized as by turning over the outer side margins. A pin 24 c is placed through the aperture, slots and an aperture in the second end 24 b of third link 24 . In the open contacts position, the spring strip causes the pin to move to the uppermost extremity of the slots and when the movable electrical contact mounted at the distal end 30 g of the longer leg engages the stationary electrical contact the pin moves downwardly in the slots placing a selected force on the stationary electrical contact. The movable contact mechanism is pivotably mounted on pin 30 h adjacent to the bight portion connecting the two legs. With particular reference to FIGS. 7-9, as push-button 16 is moved down or pulled up, first link 20 rotates about pin 20 c with rivet 20 e joining links 20 , 22 forming a first movable over center joint 3 as mentioned above and being movable between opposite sides of an imaginary line 1 extending through pin 20 c and rollers 26 . A second movable over center joint 4 is formed at rollers 26 which is movable between opposite sides of an imaginary line 2 extending through over center joint 3 and pin 24 c at second end 24 b of third link 24 . A generally vertically extending stop surface 28 is formed in housing 12 and is placed so that it limits motion of first and second movable over center joints 3 , 4 on one side of their respective imaginary lines closely adjacent thereto. When push-button 16 is pulled outwardly, as shown in FIG. 7, link 20 is rotated (counterclockwise as seen in the drawing) so that movable over center joint 3 is moved away from stop surface 28 to the other side of imaginary line 1 . First spring members 34 connected between movable contact mechanism 30 and a stationary portion of the breaker provide a bias to the movable contact mechanism, as well as the toggle mechanism, in the open contacts direction. Thus pulling the push-button outwardly opens the contacts. A second spring member, torsion spring 36 , engages third link 24 reacting against pin 24 c , and biases link 24 towards stop surface 28 to normally maintain second movable over center joint 4 on the stop surface side of imaginary line 2 . When push-button 16 is pushed inwardly as shown in FIG. 8, link 20 is rotated (clockwise as seen in the drawing) in the opposite direction against an increasing force of spring member 34 as it is stretched, tending to straighten the toggle mechanism until movable joint 3 passes a center point having a maximum resisting spring force when movable joint 3 is aligned with imaginary line 1 , and then the movable joint snaps over to the stop surface 28 . With regard to a single phase circuit breaker discussed thus far, electrical circuit breaker 10 , is connected to a circuit to be protected through terminals L 1 , L 2 . Terminal L 1 mounts stationary electrical contact 32 a and movable contact 30 a is connected to load terminal L 2 through an overload sensing mechanism to be described. A short current carrying wire or pigtail 38 is connected between terminal L 2 and a current carrying bimetallic trip arm 40 . Trip arm 40 is generally U-shaped with the end of one leg being fixedly mounted in housing 12 and connected to pigtail 38 and the end of the other leg being fixedly mounted in housing 12 and connected to a long, current carrying, flexible wire or pigtail 42 having an opposite end connected to movable contact assembly 30 and movable electrical contact 30 a . The bight portion 40 a of the trip arm is disposed adjacent one end 44 a of a connecting plate 44 horizontally slidable in housing 12 . Ambient temperature compensation is provided in circuit breaker 10 by an ambient temperature bimetal compensator member 46 . Member 46 has an upper deflectable compensator arm 46 a in the form of a strip of bimetallic material and a lower, rigid motion transfer portion 46 b having side walls or the like to provide rigidity and may be formed of bimetal as a one piece member if desired. Member 46 is mounted on rod 46 c which is rotatably mounted in housing 12 . The distal end of compensator arm 46 a is disposed adjacent to end 44 b of connecting plate 44 , opposite to end 44 a . A current overload in trip arm 40 will cause the bight portion thereof to deflect to the left as seen in the drawings resulting in opening of the contacts of the circuit breaker as will be explained below. However, a change in ambient temperature will cause both the bight portion of trip arm 40 and the distal free end of the upper compensator arm 46 a to deflect similarly to maintain essentially the same spatial relationship therebetween. A calibration assembly 48 comprising calibration arm 48 a , calibration screw 48 a and calibration plate 48 c cooperate to allow adjustment of the circuit breaker to perform properly for given over currents and ambient temperatures. Plate 48 c is fixedly mounted in housing 12 and screw 48 a is received therethrough so that rotation of screw 48 a can cause rotation of calibration arm 48 a about pivot 48 d which transfers motion through connecting plate 44 to rotate compensator arm 46 a of ambient compensator member 46 a corresponding amount. Third link 24 is preferably formed with extension 24 e, adjacent to second movable over center joint 22 c and extending toward motion transfer portion 46 b of compensated trip member 46 . When an overload occurs and bight 40 a deflects to thereby move connecting plate 44 , the connecting plate will cause bimetal compensator 46 to rotate counterclockwise as viewed in the drawings and transfer motion and force to extension 24 e thereby moving the second movable joint 4 away from stop surface 28 and past the center, imaginary line 2 , allowing spring member 34 to open the contacts. Using the second movable over center joint to trip the circuit breaker results in a trip free device. That is, even if the push-button is held down in the depressed position as shown in FIGS. 4 and 9, motion transfer portion 24 e prevents the second movable joint 4 from moving back over imaginary line 2 . Both movable joints must on the stop surface side of their respective imaginary lines 1 , 2 in order for the contacts to be in the closed contacts position. In the above description a single phase has been described, however, it applies as well to a multiphase device in which devices for more than one phase are ganged together to protect two or more phases. In such a ganged device, the toggle mechanism and push-button remains the same for the phase described above with the devices for the other phases provided with similar tripping mechanisms cooperating through the single toggle mechanism. With reference to FIGS. 2 and 3 which show a circuit breaker having three ganged phase devices 5 , 6 and 7 , shown without housing 12 , center phase 6 is the same as described above. Ambient temperature bimetal compensator member 46 has spaced apart compensator arms 46 a , one aligned with each phase extending upwardly from transversely extending portion 46 d with motion transfer portion 46 b extending downwardly from the center compensator arm 46 a . The compensator arms and transversely extending portion 46 d are fixedly attached to rotatable rod 46 c . Each phase is provided with a connecting plate 44 , trip arm 40 and calibration mechanism 48 as in the center phase. Thus an overload in a trip arm 40 of any of the phases will cause the respective connecting plate to slide over and push the distal end portion of the respective upper compensator arm 46 a causing rod 46 c to rotate and in turn move motion transfer portion 46 b which moves extension 24 e of third link 24 and second movable over center joint 4 away from the stop surface 28 across imaginary line 2 to trip the circuit breaker to the open contacts position. A circuit breaker made in accordance with the invention as described above does not have a latch mechanism as used in typical prior art devices which results in avoiding friction associated with latches and concomitant problems with changing frictional forces over time which adversely affect calibration of the device. In circuit breaker devices made in accordance with the invention in which a plurality of phases are ganged together, further advantages are obtained by reducing the complexity of the design and significantly decreasing the number of parts needed along with an accompanying savings in weight by virtue of employing only one toggle mechanism. The toggle mechanism movable over center joints provide repeatable operational forces while the reset and pull-out forces can be independently adjusted without affecting the trip of contact forces. Although the invention has been described with regard to certain preferred embodiments thereof, variations and modifications will become apparent to those skilled in the art. For example, although a push-button is shown and described for rotating first link 20 , other force applying members can be used if desired, such as a toggle or rocker mechanism, known in the art. The particular configurations and lengths of the several links of the toggle mechanism can be varied to provide different contact set and reset forces, amount of contact opening and the like. Further, the toggle mechanism of the invention can be used with other circuit interrupting devices such as thermostats for example. Various actuation mechanisms can be used such as solenoid, piezo, thermal, magnetic and the like. The movable contact mechanism can be pre-loaded as described, snap acting, spring loaded cantilever, dual contact and the like. It is, therefore, the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.
An electric circuit breaker ( 10 ) has a toggle mechanism ( 18 ) having two movable over center joints ( 3, 4 ) connected between a push-button ( 16 ) and a movable contact mechanism ( 30 ). When the push-button is depressed a first link rotates bringing the first movable over center joint ( 3 ) across a center position represented by a first imaginary straight line ( 1 ) to a stop surface ( 28 ). A spring member ( 36 ) provides a bias which acts on the second movable over center joint ( 4 ) normally maintaining the second movable joint against the stop surface so that with the two movable over center joints biased against the stop surface the movable contact mechanism is moved to a closed contact position when the push-button is depressed. An overload responsive member transfers motion to the second movable over center joint ( 4 ) upon the occurrence of a selected overload and moves the second over center joint across a center position represented by a second imaginary straight line ( 2 ) allowing the contacts opening spring ( 34 ) to move the movable contact mechanism to the open contacts position providing a trip free operation. The circuit breaker can be formed for a single phase or it can be formed for multiphase operation in which additional ganged phases have no toggle mechanism but do have separate ambient temperature compensated trip arms and overload responsive members which operate through the single toggle mechanism.
7
BACKGROUND OF THE INVENTION This invention relates to a method and apparatus for the interrogation of sensors, with particular—but by no means exclusive—reference to semiconducting organic polymer based gas sensors. There is a great deal of current interest in the use of semiconducting organic polymers in gas sensing applications, since such polymers display rapid gas adsorption/desorption kinetics, relatively high sensitivities and responses which broadly mimic the response of the human olfactory system (see, for example, Persaud K C, Bartlett J G and Pelosi P, in ‘Robots and Biological Systems: Towards a new bionics?’, Eds. Dario P, Sandini G and Aebisher P, NATO ASI Series F: Computer and Systems Sciences 102 (1993) 579). A typical sensor comprises a pair of electrodes bridged by at least one layer of semiconducting organic polymer; transduction is usually accomplished by measuring changes in the dc resistance of the sensors, these changes being induced by adsorption of gaseous species onto the polymer. SUMMARY OF THE INVENTION British Patent GB 2 203 553 discloses an improved interrogation method whereby an ac electric signal is applied to the sensor, and changes in an ac impedance quantity, such as resistance, reactance, or capacitance, are measured as a function of ac frequency. One advantage of this approach is the increase in the information derived from a single sensor: in contrast to the single measurement made with the dc transduction technique, a plurality of measurements are made (at a variety of ac frequencies). However, sweeping the ac frequency is a relatively cumbersome process, requiring an expensive Impedance Analyser. The present invention provides an improved means of performing multifrequency measurements of sensors in which time domain measurement techniques are accompanied by an appropriate transformation to the frequency domain. According to one aspect of the invention there is provided a method for interrogating a sensor comprising the steps of: applying a periodic electrical signal to the sensor; obtaining a signal therefrom; and performing an operation on the obtained signal to obtain the sensor response at a plurality of frequencies, said operation including a transformation to the frequency domain of said signal or a quantity related to said signal. The sensor may be a gas sensor and may comprise semiconducting organic polymer. Alternatively, the gas sensor may be a metal oxide, bulk acoustic wave or surface acoustic wave device. The periodic electrical signal may be a pseudo random binary signal (PRBS), which may be in the form of a m-sequence. The periodic electrical signal may be a Golay code, a Walsh function or any related periodic code. The operation may comprise a Fourier transformation. Cross correlation may be employed in order to obtain the multifrequency sensor response function. The sensor response may be obtained by coherent demodulation of said signal. Alternatively, co-variance may be employed in order to obtain the multifrequency sensor response function. According to a second aspect of the invention there is provided a sensor interrogation apparatus comprising: periodic electrical signal generator means for applying a periodic electrical signal to said sensor; signal collection means for obtaining an electrical signal from said sensor; and time to frequency domain transformation means arranged to transform the obtained electrical signal to the frequency domain. The sensor may be a gas sensor, which may comprise semiconducting organic polymer. Alternatively, the gas sensor may be a metal oxide, bulk acoustic wave or surface acoustic wave device. The signal collection means may comprise a load resistor. The time to frequency domain transformation means may comprise coherent demodulation means. The time to frequency domain transformation may comprise computing means adapted to perform Fourier transformations. The periodic electrical signal generator means may comprise a PRBS generator, which may itself comprise shift registers. The periodic electrical signal generator means may comprise a Golay code, a Walsh function generator, or a generator generating any related periodic code. BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of a method and apparatus according to the invention now be described with reference to the accompanying drawings, in which: FIG. 1 shows a first embodiment of an interrogation apparatus; FIG. 2 shows a coherent demodulator; FIG. 3 is a circuit diagram of a multi-frequency data acquisition card; FIG. 4 shows a) the entire input PRBS and b) an expanded portion thereof; FIG. 5 shows the Fourier transform of the input PRBS of FIG. 4 a; FIG. 6 shows a) the entire output PRBS when a sensor is exposed to air and b) an expanded portion thereof; FIGS. 7 a and 7 b show Fourier transform spectra of the output PRBS of FIG. 6 a; FIG. 8 shows a) the entire output PRBS when a sensor is exposed to methanol vapour and b) an expanded portion thereof; FIGS. 9 a and 9 b show Fourier transform spectra of the output PRBS of FIG. 8 a ; and FIG. 10 shows dissipation factors obtained when the sensor is exposed a) to air and b) to methanol vapour. FIGS. 1 and 2 illustrate a method and apparatus for interrogating a sensor in which: periodic electrical signal is applied to the sensor; a signal is obtained therefrom; and said signal is coherently demodulated to obtain sensor responses at a plurality of frequencies. DETAILED DESCRIPTION FIG. 1 shows an interrogation system according to the invention for a gas sensor 12 comprising a PRBS generator 10 , a load resistor 14 and a coherent demodulator 16 . The system further comprises a timing and control circuit 18 , data acquisition card 20 , power supply 22 and gas sampling system 24 . The power supply 22 provides electrical power for the PRBS generator 10 , coherent demodulator 16 , timing and control circuit 18 , data acquisition card 20 and gas sampling system 24 . The timing and control circuit 18 provides stable clock pulses for the PRBS generator 10 , and intermediate frequencies (defined below) for the coherent demodulator 16 via a crystal oscillator and programmable dividers (not shown). The circuit 18 further provides control signals to control the gas sampling system 24 and data acquisition card 20 . The functions of the system are i) to deduce the multifrequency sensor 12 response and ii) to monitor changes in this response on exposure of the sensor 12 to a gas. The gas sampling system 24 permits such exposure of sensor 12 to a gas of interest, and allows purging of the sensor 12 and introduction of a reference gas (which may be the purging gas). The PRBS generator 10 accepts clock pulses from the timing and control circuit 18 and generates a maximum length sequence (m sequence) of N=2 n −1 where n is an integer and is 4 in the present example. If the clock frequency is f c, with a corresponding time interval Δt, then the PRBS generated has a period T o given by: T o =(2 n −1)Δt   (1) with a corresponding fundamental frequency f p given by: f p = f c 2 n - 1 ( 2 ) Intermediate, or overtone, frequencies f i are given by: f i = f c i ( 3 ) where i=1,2, . . . 2 n −2. In this first embodiment the PRBS generator 10 is a 4 bit parallel access shift register together with a quadruple 2-input exclusive—OR gate. The OR gate generates the input signal to the shift register by the exclusive—OR combination of the third and fourth bit of the shift register, and thus the circuit goes through a maximum of 15 states. The PRBS generated thereby is applied to the sensor 12 , which may be of the type wherein a layer of semiconducting organic polymer such as polypyrrole is deposited on and between two metal electrodes so as to effect an electrical connection. The signal across the load resistor 14 is then coherently demodulated at intermediate frequencies f i = f c i where i=1,2 . . . 8 (i.e. harmonics are taken up to −3 dB) by the coherent demodulator 16 . The sensor response at these frequencies is obtained thereby. A schematic diagram of the coherent demodulator (essentially a two channel cross correlation operator) is shown in FIG. 2 . The input 26 —the voltage across the load resistor 14 —is multiplied in one channel by sin (w i ) and in a second channel by cos (w i ) where w i is the radian frequency corresponding to cyclical frequency f i . These multiplication functions are performed by a quadrature amplitude modulator based on a programmable four channel operational amplifier. The modulated signals are low pass filtered by second order active low pass filters 28 , 30 , and added together with a summing operational amplifier 32 . The resulting output signal from the demodulator 16 is sampled at the appropriate rate, converted into a digital signal and loaded into memory by the data acquisition card 20 . Data may be transferred therefrom into a computer for further processing and display. The demodulator 16 may be used to obtain the system response at a chosen frequency, or a set of lines may be selected and the demodulation performed in parallel. It may be possible to derive further information from phase angle data. The two primary advantages of periodic signals are the ease with which they may be recognised in the presence of noise and the substantially unbiased estimate of the system response—in this case the multifrequency response of the sensor—which they provide. A particularly preferred embodiment of such periodic signals is a pseudorandom binary signal which, since its pulseform is deterministic, can be recreated as desired providing that the sequence start time and length are known. The frequencies of the PRBS sequence are dictated by the gas sensor employed. Typically, frequencies in the range 0.1-1.0 MHz are required, but this range should not be considered a limiting one. Frequencies between μHz to 100 MHz or greater may be routinely generated. The PRBS is preferably bipolar at voltage levels between±0.1 to 1.0.V, but this should not be considered a limiting requirement either. In a second embodiment a 4 sensor semiconducting organic polymer array is connected to a multi-frequency acquisition card. FIG. 3 is a circuit diagram of the card. PRBS is generated by a PRBS generator (not shown) and input to the card via PRBS inlet 34 and acquiring inlet 36 . The PRBS signal is at this stage in the form of 0-5V TTL signals. Circuitry 38 converts this input signal into a bipolar PRBS code of magnitude±0.25V. The use of bipolar signal is preferable since unipolar signal causes drift in sensor output. Circuitry 40 , which includes a tuning inductor 42 and DIP switches 44 , controls the application of the PRBS to any selected sensor in the 4 sensor array (not shown). A voltage output from the selected sensor is obtained via a 10KΩ load resistor 46 . Circuitry 48 produces a bipolar output of maximum range=2V. This output is taken across for storage on a computer. Subsequent analysis is also performed on the computer. The computer also supports software which controls the system variables. In the present example 16 shift register stages are employed (tap point at the 4th stage) producing a sequence length of 65535 clock pulses. The ADC prescaler was set to 20 MHz acquisition frequency and a PRBS prescaler value of 8 was employed (i.e. the shift frequency was 2.5 MHz and each data point corresponds to 0.4 μs). FIG. 4 a shows the total PRBS applied to the gas sensor. At this scale, such a representation is not very revealing. FIG. 4 b shows an expanded portion of the PRBS train. FIG. 5 shows the spectrum obtained when a fast Fourier Transformation (FFT) is performed on the PRBS of FIG. 4 a by the computer. This is the frequency domain equivalent of the input to the sensor. The PRBS is intended to concentrate energy mainly in the region up to about 200 KHz. FIG. 6 shows the output from the sensors, measured across the load resistor 46 , when the sensor is exposed to air (a gas sampling system similar to that described with regard to FIG. 1 is employed). FIG. 6 a shows the complete PRBS output—which, even at this level of resolution is clearly different from the input signal of FIG. 4 a —and FIG. 6 b shows an expanded portion. Interestingly, the delta-function like spikes of the PRBS are now somewhat distorted in appearance : this is undoubtedly due to the finite inductance and capacitance of the sensor. FIGS. 7 a and 7 b show the frequency domain spectrum obtained by performing a FFT on the data of FIG. 6 a. FIGS. 8 a and 8 b show the time domain output signal obtained when the sensor is exposed to methanol vapour. FIGS. 9 a and 9 b show the corresponding frequency domain spectrum obtained when a FFT is performed on the output shown in FIG. 9 a . Clearly the spectrum is different to the spectrum obtained in air (FIG. 7 a ), showing that this interrogation technique can produce gas sensitive data. Interestingly, the absolute power of the frequency spectrum of FIG. 9 a , and the output signal amplitude of FIG. 8 a are smaller than the corresponding values obtained with air. This is consistent with the increase in dc resistance obtained when the sensor is exposed to methanol using the prior art dc resistance interrogation technique. FIGS. 10 and 10 b show dissipation factors obtained, respectively, in air and methanol. The dissipation factor is obtained by dividing the real part of frequency response by the imaginary part of the response (plus an increment of 0.01 to prevent the occurence of a singularity). Distinctly different peak dissipation factors are obtained, viz, ca. 60 KHz for air and ca. 150 KHz for methanol. It will be appreciated that it is not intended to limit the invention to the above examples only, many variations, such as might readily occur to one skilled in the art, being possible without departing from the scope thereof. For instance, other forms of periodic signals may be applied to the sensor. An example is a Golay code, which is a pair of complementary series exhibiting autocorrelation functions having self noise sidelobes of equal magnitude but opposite sign. The sum of the two individual autocorrelation functions is a close approximation to the ideal Dirac delta function (see, for example. Ding ZX and Payne Pa., Meas. Sci. Technol., 1 (1990) 158). Another example of a suitable periodic signal is a Walsh function. It should be noted that other methods may be employed to derive the frequency domain response spectrum from the time domain PRBS interrogating sequence. One approach is to transform the time domain PRBS input x(t) and the sensor output y(t) to produce a frequency domain input X(ω) and output Y(ω). The sensor frequency response S(ω) is then given by: S  ( ω ) = Y  ( ω )  X *  ( ω ) X  ( ω )  X *  ( ω ) ( 4 ) Another approach is to cross correlate and auto-correlate in the time domain and to transform the correlations to the frequency domain to yield spectral density functions. If the auto-correlation function between sensor output and PRBS input at time difference τ is R xy (τ), then the cross spectral density function Φ xy (ω) is given by: Φ xy (ω)=∫ R xy (τ)exp(−iωτ) dτ  (5) where in practice the upper and lower limits of the integral will be finite. The system response S(ω) is now given by: S  ( ω ) = Φ xy  ( ω ) Φ xx  ( ω ) ( 6 ) where Φ xy (ω) is the power spectral density function. Appropriate transformations such as a fast Fourier transform (FFT) may be applied for these purposes. It may be desirable to compute the auto-correlation function between the sensor output when exposed to unknown gas and the sensor output in the presence of an air reference flow. Covariance techniques may be applied as an alternative to cross correlation. It should be noted further that the present invention is not limited to semiconducting organic polymer based sensors, but rather, extends to any sensor which may be interrogated by application of multifrequency signals. Such sensors include any material that can be treated as a dielectrical and which is affected by its environment, such as metal oxides, non-polymer semiconductors and organic polymers which are not semiconducting. Bulk acoustic wave and surface acoustic wave devices are also within the scope of the invention. While gas sensing is of particular interest, it is possible to measure, using the methods and apparatus of the invention, the response of sensors to other influences, such as temperature and pressure, if they have any response thereto, either independently of or in conjunction with their possible response to the presence of a gas or mixture of gases. In any case, it is understood that the use of semiconducting organic polymer based sensors in gas sensing includes the detection of odours and volatile species, and, further, that such sensors may be employed in other applications, such as liquid phase analyte detection. While the apparatus described with reference to the drawings is appropriate to a laboratory or field instrument, it is also possible to configure the sensor for example as a smart tag which could be included in food packaging and scanned using electromagnetic radiation techniques to reveal its resonant frequency, which would be expected to change as the composition of gases changed within the packaging, which might reveal the age of the goods or some other factor such as whether the goods have been exposed to a temperature above the recommended storage temperature or if the package seal has failed. Such sensors with their associated circuitry could be manufactured inexpensively and interrogated using a hand-portable scanning device for warehouse or supermarket use. The scanning device could comprise a database showing the expected response of various sensors—sensors used for meat products, for example, might be quite different and have a different characteristic response from sensors used for dairy products or packed vegetables. While a system as described involving time to frequency domain transformation means would be very appropriate in the analysis of signals emitted by such smart tags in response to an interrogation signal, it may well be the case that the smart tags could incorporate some analytical circuitry that emitted—or failed to emit—a recognisable signal consequent upon some change in the sensor's environment, and such other analysis method could be used independently of or in conjunction with the time to frequency transformation based analysis of the present invention.
There is disclosed a method for interrogating a sensor comprising the steps: applying a periodic electrical signal to the sensor; obtaining a signal therefrom; and performing an operation on the obtained signal to obtain the sensor response at a plurality of frequencies, said operation including a transformation to the frequency domain of said signal or a quantity related to said signal.
0
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a piezoelectric device, and more particularly, to a piezoelectric device in which an element portion, such as a resonator or a filter, is disposed on a piezoelectric substrate. [0003] 2. Description of the Related Art [0004] A piezoelectric device has been proposed in which in which an IDT electrode disposed on a piezoelectric substrate is covered with a cover layer. [0005] For example, in a piezoelectric device 110 shown in a cross-sectional view in FIG. 8 , on one main surface 111 a of a piezoelectric substrate 111 having a conductive pattern including an IDT electrode 112 , and pad electrodes 113 , a frame-like supporting layer 120 made of a resin is arranged so as to surround an IDT-forming region where an IDT electrode 112 is arranged, and a cover layer 130 made of a resin is disposed on the supporting layer 120 . Furthermore, the piezoelectric device 110 is entirely covered with an outer resin 140 , and an IDT space 114 surrounding the IDT electrode 112 is sealed (see, for example, Japanese Unexamined Patent Application Publication No. 2006-352430). [0006] In the piezoelectric device in which the IDT electrode is covered with the cover layer as described above, as shown in a perspective view of FIG. 6 , the supporting layer 120 which supports the cover layer is spaced apart from the IDT electrode 112 so as not to adversely affect the region in which vibration propagates on the piezoelectric substrate 111 (the region in which the IDT electrode 112 is formed and its vicinity). The coefficient of linear expansion of the supporting layer 120 made of a resin is greater than the coefficient of linear expansion of the piezoelectric substrate 111 . Therefore, when there is a change in temperature, thermal stress occurs between the piezoelectric substrate 111 and the supporting layer 120 , and under the influence thereof, strain occurs in the region in which vibration propagates on the piezoelectric substrate 111 , thus changing the vibration propagation state. As a result, temperature characteristics of the piezoelectric element including the IDT electrode 112 are degraded. [0007] The degradation in temperature characteristics is believed to be improved by increasing the distance between the IDT electrode 112 and the supporting layer 120 . [0008] However, when a structure in which a supporting layer 120 is disposed close to an IDT electrode 112 on a piezoelectric substrate 111 , as shown in FIG. 7A which is a cross-sectional view of a main portion, is changed to a structure in which a supporting layer 120 x is spaced away from the IDT electrode 112 such that the distance between the IDT electrode 112 and the supporting layer 120 x is increased as shown in FIG. 7B which is a cross-sectional view of a main portion, a cover layer 130 on the supporting layer 120 x sags and attaches to the IDT electrode 112 , which degrades characteristics. In particular, in the case in which molding is performed with a resin, the cover layer 130 easily sags under pressure during molding, and characteristics are significantly degraded. [0009] Furthermore, because of the increase in the distance between the IDT electrode and the supporting layer, design freedom is reduced. In addition, the size of piezoelectric devices cannot be reduced. SUMMARY OF THE INVENTION [0010] To overcome the problems described above, preferred embodiments of the present invention provide a piezoelectric device in which temperature characteristics can be improved without changing the distance between an IDT electrode and a supporting layer. [0011] A piezoelectric device according to a preferred embodiment of the present invention includes a piezoelectric substrate, a conductive pattern which is provided on one main surface of the piezoelectric substrate and which includes an IDT electrode, a supporting layer which is arranged on the one main surface of the piezoelectric substrate so as to surround the periphery of an IDT-forming region in which the IDT electrode is provided and which has a thickness greater than that of the IDT electrode, and a cover layer which is arranged on the supporting layer and which covers the IDT-forming region. The supporting layer includes removed sections provided at a plurality of positions at least in a region close to the IDT-forming region, the removed sections being obtained by partially removing a portion of the supporting layer to be bonded to the one main surface of the piezoelectric substrate. [0012] Since the supporting layer includes the removed sections provided in the region close to the IDT-forming region, the bonding area between the supporting layer and the piezoelectric substrate is decreased in the region close to the IDT-forming region. Thereby, thermal stress is reduced, and the influence of thermal stress on the region in which vibration propagates on the piezoelectric substrate (the IDT-forming region and its vicinity) is decreased. Therefore, the temperature characteristics of the piezoelectric device are improved. [0013] The removed sections provided in the supporting layer can be configured according to various preferred embodiments of the present invention. [0014] According to one preferred embodiment of the present invention, the removed sections are defined by a plurality of slits arranged so as to extend from an opening, which is provided in the inner peripheral surface facing the IDT region of the supporting layer, in a direction away from the IDT-forming region. [0015] In this case, in the region of the supporting layer close to the IDT-forming region, the area of the piezoelectric substrate which the supporting layer is bonded to is significantly decreased by the slits. Therefore, the temperature characteristics are greatly improved. [0016] According to another preferred embodiment, the removed sections are defined by holes, the entire circumference of each of which is surrounded by the supporting layer. [0017] In this case, when viewed in perspective in a direction perpendicular to one main surface of the piezoelectric substrate, for example, a plurality of holes may preferably be arranged in one line or in two or more lines along the outer periphery of the IDT-forming region. Alternatively, strip-shaped long holes may be arranged so as to extend along the outer periphery of the IDT-forming region. [0018] Preferably, the removed sections pass through the supporting layer between two main surfaces in contact with the piezoelectric substrate and the cover layer. [0019] The removed sections passing through the supporting layer can be formed in the same process as that for patterning of the supporting layer, without adding an additional step. [0020] Preferably, the supporting layer is made of a photosensitive resin. [0021] In this case, the supporting layer can be formed with high accuracy by a photolithographic technique, for example. [0022] Preferably, the supporting layer is made of a photosensitive polyimide resin. [0023] By using the photosensitive polyimide resin, high reliability can be ensured. [0024] Preferably, the supporting layer is made of a photosensitive silicone resin. [0025] By using the photosensitive silicone resin, a low-temperature curing process may be used. [0026] Preferably, the supporting layer is made of a photosensitive epoxy resin. [0027] By using the epoxy resin, a supporting layer with higher resolution can be formed. Furthermore, a low-temperature curing process may be used. [0028] Preferably, the cover layer is made an epoxy film resin. [0029] By using the epoxy film resin, a low-temperature curing process may be used. [0030] Preferably, the cover layer is made of a polyimide film resin. [0031] By using the polyimide film resin, high reliability can be ensured. [0032] Preferably, the piezoelectric device further includes a via hole which is formed by subjecting the supporting layer and the cover layer to laser machining at one time, for example. [0033] In this case, the via hole can be formed with high accuracy at low cost. [0034] Preferably, the piezoelectric device further includes a via hole which is formed by subjecting the supporting layer and the cover layer to sandblasting at one time, for example. [0035] In this case, the via hole can be formed at low cost. [0036] Preferably, the piezoelectric device further includes a via hole which passes through the supporting layer and the cover layer, and an under-bump metal formed by Au/Ni electrolytic plating in the via hole. [0037] In this case, the under-bump metal can be accurately formed. [0038] Preferably, the piezoelectric device includes at least two items selected from the group consisting of (i) the supporting layer made of at least one of a photosensitive resin, a photosensitive polyimide resin, a photosensitive silicone resin, and a photosensitive epoxy resin, for example, (ii) the cover layer made of at least one of an epoxy film resin and a polyimide film resin, for example, and (iii) a via hole formed by subjecting the supporting layer and the cover layer to laser machining or sandblasting at one time. [0039] According to various preferred embodiments of the present invention, it is possible to improve temperature characteristics of a piezoelectric device without changing the distance between an IDT electrode and a supporting layer. [0040] The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0041] FIG. 1 is a cross-sectional view of a piezoelectric device according to a preferred embodiment of the present invention. [0042] FIG. 2 is a cross-sectional view of the piezoelectric device shown in FIG. 1 . [0043] FIG. 3 is a graph showing temperature characteristics the piezoelectric devices shown in FIG. 1 . [0044] FIG. 4 is a cross-sectional view of a piezoelectric device according to another preferred embodiment of the present invention. [0045] FIG. 5 is a cross-sectional view of a piezoelectric device according to another preferred embodiment of the present invention. [0046] FIG. 6 is a perspective view of a known piezoelectric device. [0047] FIGS. 7A and 7B include cross-sectional views, each showing a main portion of the piezoelectric device shown in FIG. 6 . [0048] FIG. 8 is a cross-sectional view of a known piezoelectric device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0049] Preferred embodiments of the present invention will be described below with reference to FIGS. 1 to 5 . [0050] FIG. 1 is a cross-sectional view of a piezoelectric device 10 . As shown in FIG. 1 , the piezoelectric device 10 is a surface acoustic wave (SAW) filter in which an element portion is disposed on a piezoelectric substrate 11 . An upper surface 11 a , which is one main surface of the piezoelectric substrate 11 , is provided with a conductive pattern including an interdigital transducer (IDT) electrode 12 , which is a comb-shaped electrode, pad electrodes 13 , and wiring (not shown) extending between the IDT electrode 12 and the pad electrodes 13 . A supporting layer is arranged in a frame shape in the periphery of an IDT-forming region in which the IDT electrode 12 is provided. The thickness of the supporting layer 20 is greater than the thickness of the conductive pattern, such as the IDT electrode 12 . The supporting layer 20 is also disposed on the pad electrodes 13 . [0051] A cover layer 30 is arranged on the supporting layer 20 , and the surroundings of the IDT electrode 12 provided on the piezoelectric substrate 11 are covered with the supporting layer and the cover layer 30 which are insulating members to provide an IDT space 14 . In the upper surface 11 a of the piezoelectric substrate 11 , surface acoustic waves freely propagate in a portion adjacent to the IDT space 14 . [0052] As shown in FIG. 1 , via holes (through holes) 16 which extend to the pad electrodes 13 provided on the upper surface 11 a of the piezoelectric substrate 11 are provided in the supporting layer 20 and the cover layer 30 . Each of the via holes 16 is filled with an under-bump metal 17 , and a solder bump 18 which is exposed to the outside is provided on the under-bump metal 17 . [0053] The piezoelectric device 10 is, for example, used as a portion of a module, and after a plurality thereof are mounted on a substrate, the periphery is molded with a resin. [0054] FIG. 2 is a schematic cross-sectional view taken along the line X-X in FIG. 1 . In FIG. 2 , the via holes 16 and the under-bump metal 17 are omitted. [0055] As shown in FIG. 2 , the supporting layer 20 includes a plurality of slits 24 provided as removed sections in a portion close to the IDT-forming region in which the IDT electrode 12 is provided. The slits 24 are arranged in a comb shape, i.e., in parallel to each other with a predetermined distance therebetween, and extend from an opening 24 a provided in the inner peripheral surface 22 of the supporting layer 20 in a direction extending away from the IDT-forming region. The slits 24 are provided at least in the portion close to the IDT-forming region and the slits may extend to a portion distant from the IDT-forming region. [0056] By forming the slits 24 in the supporting layer 20 , the bonding area between the supporting layer 20 and the piezoelectric substrate 11 is decreased. Thereby, thermal stress is reduced, and the influence of thermal stress on the region in which vibration propagates on the piezoelectric substrate 11 (the IDT-forming region and its vicinity) is decreased, and therefore, it is possible to improve the temperature characteristics. [0057] Next, a specific manufacturing example of a piezoelectric device 10 will be described. A plurality of piezoelectric devices 10 are collectively manufactured as a collective substrate. [0058] First, a conductive pattern including an IDT electrode 12 and pad electrodes 13 is formed on a piezoelectric substrate 11 . The conductive pattern is formed using a method capable of achieving height accuracy and surface flatness, such as a vapor-deposited metal film with a thickness of about 1 μm to about 2 μm, for example. An element portion having the IDT electrode 12 and element wiring to be connected to the IDT electrode 12 is formed with the conductive pattern. [0059] Next, a SiO 2 film or a two-layered film of SiN/SiO 2 is preferably formed by sputtering, for example, on the surface of the element portion. In portions, such as pad electrodes 13 defining underlying electrodes for an under-bump metal 17 , from which the SiO 2 film and the SiN film are required to be removed, the SiO 2 film and the SiN film are preferably removed by dry etching, for example. [0060] Next, in order to form an IDT space 14 and slits 24 , a supporting layer 20 is formed so as not to overlap the vibration portion. That is, for example, a photosensitive polyimide resin is applied onto the piezoelectric substrate 11 , the IDT space 14 (a portion directly above the IDT electrode 12 and a periphery of the IDT electrode 12 in a range of about 5 μm to about 15 μm, for example) and the slits 24 are formed by a photolithographic technique, and at the same time, a region with a width of about 100 μm, for example, having a dicing line in the approximate center thereof is also provided. In FIG. 2 , the size of the IDT space 14 represented by symbols A and B is preferably in a range of about 50 μm×about 50 μm to about 1000 μm×about 400 μm, for example. Although the photosensitive polyimide resin is used for the supporting layer 20 , a photosensitive epoxy or photosensitive silicone resin may be used. The thickness of the supporting layer 20 is preferably about 15 μm, but may be in a range of about 10 μm to about 30 μm, for example. [0061] Next, a cover layer 30 is formed, for example, by lamination on the supporting layer 20 . Then, in portions to which solder balls defining external terminals are to be connected, the cover layer 30 and the supporting layer 20 are removed by laser machining to form via holes 16 with a diameter of about 50 μm to about 150 μm. Although a non-photosensitive epoxy film resin is used for the cover layer 30 , a non-photosensitive polyimide film may be used. The thickness of the cover layer 30 preferably is about 30 μm, but may be in a range of about 30 μm to about 50 μm. Furthermore, the via holes 16 may be formed by sandblasting. The portions of the via holes 16 located in the supporting layer 20 may be formed in the photolithography step in the process of forming the supporting layer 20 . [0062] Organic substances on the surface of the pad electrodes 13 exposed to the bottoms of the via holes 16 are removed by dry etching. Then, the via holes 16 are filled with Cu, Ni, or other suitable material by electrolytic plating, for example, and Au (about 20 μm to about 1000 nm thick) for oxidation prevention is preferably electrolytically plated on the surface to form an under-bump metal 17 , for example. The under-bump metal 17 may preferably be formed by electroless plating, for example. The surface of the under-bump metal 17 is formed so as to recede (be concave) from the surface of the cover layer 30 within a range of about 0 μm to about 10 μm. [0063] Next, a solder paste of Sn—Ag—Cu or other suitable material is printed immediately above the under-bump metal 17 through a metal mask, and the solder is fixed to the under-bump metal 17 by heating at a temperature at which the solder paste is melted, for example, at about 260° C. Flux is removed with a flux cleaner, and thereby, spherical solder bumps 18 are formed. [0064] Then, chips (individual pieces) are cut out by a method, such as dicing, for example. A piezoelectric device 10 is thereby completed. [0065] A graph of FIG. 3 shows differences in the temperature coefficient between each of SAW filters of Fabrication Examples (1) and (2) and a SAW filter of Comparative Example which is the same as the SAW filter of Fabrication Example (1) or (2) except for the absence of slits. [0066] In Fabrication Examples (1) and (2), the sizes of the IDT space 14 and slits 24 formed in the photolithography step in the process of forming the supporting layer, which are illustrated in FIG. 2 , are as follows: [0067] IDT space size (A×B): about 50 μm×about 50 μm in each of Fabrication Examples (1) and (2) [0068] Slit length (L): about 15 μm in each of Fabrication Examples (1) and (2) [0069] Slit spacing (W): about 20 μm in Fabrication Example (1) and about 50 μm in Fabrication Example (2) [0070] Slit width (S): about 50 μm in each of Fabrication Examples (1) and (2) [0071] Distance (D) between IDT-forming region and supporting layer: about 30 μm in each of Fabrication Examples (1) and (2) [0072] In FIG. 3 , the vertical axis represents the level of each of Fabrication Examples (1) and (2) relative to Comparative Example (temperature coefficient=0), and its units of measure are ppm/° C. A lower value relative to the standard (=0) indicates a larger temperature improvement. The asterisk (4.0 dBfL) represents the data at a point on the low frequency side in which the filter characteristic is at a level 4.0 dB lower than the through level. The solid circle (4.0 dBfH) represents the data at a point on the high frequency side in which the filter characteristic is at a level 4.0 dB lower than the through level. The solid diamond (5.0 dBfL) represents the data at a point on the low frequency side in which the filter characteristic is at a level 5.0 dB lower than the through level. The solid square (5.0 dBfH) represents the data at a point on the high frequency side in which the filter characteristic is at a level 5.0 dB lower than the through level. The solid triangle (47 dBfL) represents the data at a point on the low frequency side in which the filter characteristic is at a level 47 dB lower than the through level. [0073] As shown in the graph of FIG. 3 , by providing slits 24 , the temperature coefficient decreases, and it is possible to improve temperature characteristics without changing the distance between the IDT electrode and the supporting layer. [0074] A preferred embodiment of the removed sections provided in a supporting layer will be described with reference to FIG. 4 . [0075] FIG. 4 is a cross-sectional view schematically showing a cross-section of a supporting layer 20 a taken along the piezoelectric substrate 11 as in FIG. 2 . As shown in FIG. 4 , the supporting layer 20 a which surrounds an IDT-forming region 12 a in which the IDT electrode is provided includes a plurality of holes 26 defining removed sections in a portion close to the IDT-forming region 12 a . The holes 26 are spaced away from the inner peripheral surface 22 a of the supporting layer 20 a , and the entire circumference of each of the holes 26 is surrounded by the supporting layer 20 a . FIG. 4 illustrates an example in which the holes 26 are arranged in one line along the inner peripheral surface 22 b of the supporting layer 20 b . However, the holes may be arranged in various ways, and for example, may be arranged in two or more lines and may be arranged in a scattered pattern. Furthermore, the holes are arranged at least in the portion close to the IDT-forming region 12 a and may also be arranged in the portion distant from the IDT-forming region 12 a. [0076] By forming the holes 26 in the supporting layer 20 a , the bonding area between the supporting layer 20 a and the piezoelectric substrate 11 is decreased. Thereby, thermal stress is reduced, and the influence of thermal stress on the region in which vibration propagates on the piezoelectric substrate 11 (the IDT-forming region 12 a and its vicinity) is decreased. Therefore, the temperature characteristics are improved. [0077] Another preferred embodiment of the removed sections provided in a supporting layer will be described with reference to FIG. 5 . [0078] FIG. 5 is a cross-sectional view schematically showing a cross-section of a supporting layer 20 b taken along the piezoelectric substrate 11 as in FIG. 2 . As shown in FIG. 5 , the supporting layer 20 b which surrounds an IDT-forming region 12 b in which the IDT electrode is provided includes a plurality of long holes 28 defining removed sections in a portion close to the IDT-forming region 12 b . The long holes 28 are spaced away from the inner peripheral surface 22 b of the supporting layer 20 b , and the entire circumference of each of the long holes 28 is surrounded by the supporting layer 20 b . The long holes 28 extend along the inner peripheral surface 22 b of the supporting layer 20 b such that the longitudinal direction of the long holes is in parallel or substantially parallel to the inner peripheral surface 22 b . FIG. 5 illustrates an example in which the long holes 28 are arranged in two lines. However, the long holes may be arranged in various ways, and for example, may be arranged in one line or three or more lines. Furthermore, the long holes are arranged at least in the portion close to the IDT-forming region 12 a and may be also arranged in the portion distant from the IDT-forming region 12 a. [0079] By forming the long holes 28 in the supporting layer 20 b , the bonding area between the supporting layer 20 b and the piezoelectric substrate 11 is decreased. Thereby, thermal stress is reduced, and the influence of thermal stress on the region in which vibration propagates on the piezoelectric substrate 11 (the IDT-forming region 12 b and its vicinity) is decreased. Therefore, it is possible to improve temperature characteristics. [0080] As described above, by providing slits, holes, or long holes as removed sections in the supporting layer, the temperature characteristics are improved without changing the distance between the IDT electrode and the supporting layer. The slits, holes, or long holes can be formed in the same process as that for patterning of the supporting layer without adding an additional step. [0081] Furthermore, the present invention is not limited to the preferred embodiments described above, and various modifications are possible. [0082] For example, preferred embodiments of the present invention may be applied to a piezoelectric device which is sealed with an outer resin as in the conventional example shown in FIG. 8 , and removed sections may be provided in the supporting layer supporting the cover layer. Not only a SAW element, but also an element portion, such as a boundary wave element, may be provided on the piezoelectric substrate. [0083] While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.
A piezoelectric device includes a piezoelectric substrate, a conductive pattern which is provided on one main surface of the piezoelectric substrate and which includes an IDT electrode, a supporting layer which is arranged on the one main surface of the piezoelectric substrate so as to surround the periphery of an IDT-forming region in which the IDT electrode is provided and which has a thickness greater than that of the IDT electrode, and a cover layer which is arranged on the supporting layer and which covers the IDT-forming region. The supporting layer includes removed sections provided at a plurality of positions at least in a region close to the IDT-forming region, the removed sections being obtained by partially removing a portion of the supporting layer to be bonded to the one main surface of the piezoelectric substrate.
7
CROSS-REFERENCE TO RELATED APPLICATION This is a continuation-in-part of copending application Ser. No. 709,368, filed July 28, 1976, now abandoned. BACKGROUND OF THE INVENTION This invention relates to a process for treating waste water from industrial sources. In a more specific aspect, this invention relates to a process for treating waste water having a relatively high chemical oxygen demand (COD) caused by organic material which is predominantly soluble in water. It is well known in the art to use a biochemical treatment step for treating municipal sewage. Use of biochemical treatment is also known for waste water from chemical plants as evidenced by Hudson, Jr. et al, U.S. Pat. No. 3,646,239. Waste water from chemical plants generally differs substantially from municipal sewage in that it contains a higher concentration of organic matter and, in addition, this organic matter is predominantly soluble whereas in municipal sewage the organic matter is predominantly solids. The high concentration of organic matter in waste water from chemical processes makes the treatment of this water extremely difficult. For instance, in a municipal sewer plant, chemical oxygen demand may be no more than 300 to 400 milligrams per liter and a 90 percent reduction leaves the effluent within generally accepted standards, whereas with waste water from a chemical plant which may have a chemical oxygen demand of 2500 or more, a 90 percent reduction leaves the effluent still unsuitable for disposal in view of current Federal specifications requiring waste water to have a maximum COD of approximately 200 and a maximum BOD (biological oxygen demand) of approximately 20 before discharge into a river or pond. Accordingly, when high COD industrial wastes are to be treated, it is frequently necessary to supplement biotreating with another process such as chemical treatment, stripping, or adsorption. Another problem encountered in biotreating industrial wastes is that these wastes may contain chemicals which are toxic to the microorganisms. The presence of such substances retards the activity of the microorganisms and reduces their population. The result is gradually poorer biotreater performance and unacceptable BOD and COD levels in the effluent. Known methods for overcoming the problem include (1) identification and elimination of the toxins, (2) dilution of the biotreater feed to lower toxin concentration to an acceptable level, and (3) pretreating the feed in some manner such as by carbon adsorption. These methods, however, have serious disadvantages. The first may be too expensive and it may be virtually impossible to identify and eliminate the toxins; the second is also costly and may be unacceptable to Government authorities since it increases the volume of the waste stream; and the third, while effective, is also costly in that the carbon beds become loaded rather rapidly, necessitating frequent regeneration and makeup of carbon. The use of carbon to "polish" all of the final effluent prior to discharge is also known, but this can be even more expensive than the use of carbon to pretreat waste water. SUMMARY OF THE INVENTION It is an object of this invention to provide a process suitable for treating industrial waste water; it is a further object of this invention to provide a process for treating waste water having a high chemical oxygen demand generated by organic material which is predominantly soluble; it is yet a further object of this invention to provide a process for treating waste water involving the use of a conventional activated sludge process; it is still yet a further object of this invention to provide an economical process for treating waste water from an oxidative dehydrogenation process; it is an object of one embodiment of this invention to provide a process for treating waste water involving the use of activated carbon which makes efficient use of the carbon; it is still a further object of this invention to produce water having a COD of 200 or less and a BOD of 20 or less; it is still yet a futher object of another embodiment of this invention to treat industrial waste water without dilution or pretreatment using an activated sludge process; and it is still yet a further object of this invention to provide a process for biotreating waste water having a toxic content. In accordance with one embodiment of this invention, industrial waste water is passed to a conventional biotreating zone and the resulting purified water is separated into at least two streams, a discharge stream and a recycle stream which is passed into contact with activated carbon and thence back into the biotreating zone as a dilution stream. In accordance with another embodiment of this invention, industrial waste water is passed to the biological treating zone of an activated sludge system and then to a clarifier zone, the effluent from the clarifier is passed to a filtration zone and periodically the filter is backwashed to return bacteria to the system. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, forming a part thereof, wherein like reference characters denote like parts in various views, FIG. 1 is a schematic representation of a waste water treatment process in accordance with this invention; FIGS. 2 and 3 are schematic drawings of waste water treatment processes in accordance with conventional practice and the first embodiments of this invention, respectively; and FIG. 4 is a schematic representation of a waste water treatment process emphasizing the second embodiment of this invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS As used herein, the term COD (chemical oxygen demand) is a measure of the oxygen equivalent of that portion of the organic matter in a sample that is susceptible to oxidation by a strong chemical oxidant. It can be expressed either in terms of milligrams per liter or in parts per million. Tests can be run in accordance with Standard Methods for the Examination of Water and Wastewater, 13th Edition, pages 495-499, American Public Health Association, Inc. (1971). BOD (biochemical oxygen demand) is a similar test measuring the oxygen requirements for biochemical oxidation of organic matter in waste water. This test is run in accordance with "Standard Methods for the Examination of Water and Wastewater", 13th Edition, pages 489-495, American Public Health Association, Inc., New York, New York (1960). As noted in detail hereinafter, the data reported herein is sometimes in SBOD and SCOD (soluble) but there is very little solid material creating an oxygen demand so the SCOD is essentially the same as TCOD and SBOD is essentially the same as TBOD. The terms COD and BOD without more refer to TCOD (total of soluble and solids) and TBOD (total of soluble and solids). As explained hereinafter, these terms are different from TOD which is the complete total of all oxygen demand for all organic matter since the test involves burning which removes all of both the soluble and solid and also more completely oxidizes so as to give a higher value than COD. The invention is applicable to the treatment of any waste water having a relatively high COD and a relatively high percentage of the COD produced by soluble organic material and/or waste water having toxic organic ingredients. The invention is particularly applicable to waste water having a COD of 1000 or greater, preferably 2000 to 10,000 milligrams per liter. It is of particular applicability to such waste water wherein the COD is produced by organic material which is greater than 50 percent, preferably greater than 90 percent soluble. It is of particular applicability to waste water having 90 to 99 percent of the material creating the COD in the form of soluble organic matter. The invention is of primary applicability in treating waste water from chemical plants and most particularly applicable to the purification of effluents from oxidative dehydrogenation processes. Water effluent from a butane oxidative dehydrogenation plant contains appreciable amounts of oxygenated compounds. Hudson, Jr. et al, U.S. Pat. No. 3,646,239, the disclosure of which is hereby incorporated by reference, gives the background for such a dehydrogenation process. The waste water is obtained from several sources in such a plant. It is generally stripped or flashed for removal of most of the volatile oxygenated compounds which are then either burned or recycled to the dehydrogenation reactor. Hinton et al, U.S. Pat. No. 3,679,764, the disclosure of which is hereby incorporated by reference, illustrates steam stripping with recycle of overhead impurities to the dehydrogenation reactor. It is also possible to strip the waste water with inert gas and then burn the overhead. In any event, the water stream to be treated in accordance with the preferred embodiment of this invention is water from a stripper or flash step that has already had many of the impurities removed. The microorganisms for effecting the biochemical treatment can be obtained from any conventional municipal activated sludge treatment plant and conditioned simply by their presence in the effluent to be treated wherein the particular bacteria which thrive on the particular effluent will multiply and the others will die. Generally, the effective microorganisms are aerobic gram negative rod-shaped bacteria. Other known methods of obtaining the appropriate microorganisms such as from a soil sample can also be used. The organic materials primarily being treated in accordance with this invention are aldehydes, ketones, acids, and interrelated products thereof. Any conventional activated carbon can be utilized in the first embodiment of the invention such as for instance, Nuchar WVG 12 by 40 mesh activated carbon. The carbon can be regenerated in a manner well known in the art. The time and temperature for the activated carbon treatment of the recycle can be the same as that conventionally employed when activated carbon treatment is used as a tertiary treatment following a biochemical treatment. Generally, the treatment will be carried out at ambient temperature although temperatures within the range of 50° to 150° F. are satisfactory. The flow rate can be that which is conventionally utilized and is not critical. For instance a rate of 1 to 10 volumes of water per hour per volume of activated carbon is satisfactory. The exposure as measured in pounds of COD per pound of carbon is generally in the range of 0.1 to 1, preferably 0.2 to 0.4. The biochemical treatment is carried out in a conventional manner as is known in the art, the second embodiment specifically being carried out in an activated sludge plant utilizing an activated sludge tank (aerator or biological treatment zone) and clarifier with sludge recycle from the clarifier to the sludge tank, as is known in the art. It will generally be carried out at ambient temperature although the temperature can vary from 40° to 150° F. (4° to 66° C.). Time of treatment from 0.2 to 10 days in hot weather and 0.4 to 20 days in cold weather is preferred although this can vary somewhat. Where space limitations are a factor, rotating biological surface units such as the Biosurf unit solid by Autotrol Corporation are suitable for use in the first embodiment of this invention. The dilution ratio for the first embodiment of this invention is somewhat critical. Above a ratio of about 1:1 (feed:recycle) toxic constituents in the feed are sufficiently concentrated to seriously impair the biochemical treatment. Dilution in excess of the bare minimum required to counteract the effect of the toxic constituents constitutes an unnecessary waste. Accordingly, dilution ratios of 1:0.75 to 1:4, preferably 1:1 to 1:2, most preferably about 1:1, are utilized. Thus the portion recycled generally constitutes 40-80, preferably 50-67, volume percent of the clarifier effluent, the remainder being discharged without activated carbon treatment. The filter for the second embodiment of this invention can be any granular media filter of the type well known in the art. Exemplary of such filters are those using anthracite coal on top of sand, the sand being on top of garnet. The particles become progressively smaller and heavier going from the coal in the sand to the garnet. Since this filtration of clarifier effluent is relatively easy, the filter can utilize only two of these materials or even only one. Particularly, the coal alone or sand alone can be used. Backflushing is generally carried out fairly often so as to avoid killing the bacteria and to avoid excessive pressure drop. Generally, the backwash will be carried out once every 6 to 48 hours, preferably once every 12 to 36 hours, although shorter or longer times can be used. Referring now to the drawings, there is shown an exemplary utility for the instant invention in accordance with the preferred embodiment thereof wherein waste water from an oxidative dehydrogenation process is treated in accordance with the invention. In the oxidative dehydrogenation system, air and steam are passed to furnace 12 by way of process lines 10 and 11, respectively, and are heated to a reaction temperature of about 1050° F. After this the combined stream is passed by way of line 13 where it is admixed with butene introduced by way of line 14 to reactor 15. The resultant mixture of air, stream and hydrocarbon feed, specifically butene, contacts a suitable dehydrogenation catalyst is zone 15 at a reaction temperature such as from about 800° to 1200° F. whereby the butene is converted at least partially to butadiene. The effluent from the dehydrogenation zone additionally contains oxygenated hydrocarbons including carbonyls. The reactant effluent comprising unreacted hydrocarbons, dehydrogenated butene, e.g., butadiene, oxygenated hydrocarbons and water is removed from the reactor by way of line 16 and passes through condenser 17 where the water is substantially condensed to produce an aqueous phase containing a predominance of the oxygenated hydrocarbons contained in the reactor effluent. The condensate is passed to collection vessel 18 wherein the aqueous phase 19 containing oxygenated hydrocarbons is accumulated and the vaporous hydrocarbon phase is removed by way of line 20 and passed to purification and collection facilities. Recycle of the condensate phase 19 containing oxygenated hydrocarbons to the dehydrogenation zone to suppress the formation of additional oxygenated hydrocarbons as well as to conserve water is, of course, desirable for economic reasons. Aqueous phase 19 containing oxygenated hydrocarbons in zone 18 is removed by line 21 and passed to the top of steam stripper 22. Steam is introduced into the base of stripping zone 22 by way of line 23 and countercurrently contacts water descending in column 22. Column 22 can be provided with suitable packing, trays or other contact media effective for vapor-liquid contacting. The steam rising through stripping zone 22 removes a major portion of the oxygenated hydrocarbons present in the water phase introduced into the upper portion of the column. Steam and the oxygenated hydrocarbons stripped from the water phase are removed overhead from zone 22 by way of line 24 and returned to furnace 12 by introduction into steam line 11. The water phase partially stripped of oxygenated hydrocarbons is removed as bottoms from column 22 by way of line 25 and passed to kettle accumulator 26. A portion of the liquid accumulated in kettle 26 is removed and passed to retention zone 36 via line 27 and the remainder is removed by way of line 28, passed through pump 29 and through reboiler heater 30 to elevate the temperature to form steam for introduction into column 22 through line 23. The amount of stripping with steam is preferably controlled so that the amount of water equivalent to the process demand rate is vaporized and returned to furnace 12 by way of lines 24 and 11. Reboiler 30 can be heated by way of an external source of steam introduced by way of line 31, the flow rate of which can be controlled by temperature controller units sensing the temperature in the upper portion of column 22. The rate of removal of steam plus oxygenated hydrocarbons in line 24 can be controlled by a flow rate controller set to pass a certain flow rate based on the flow rate in line 11 so that a combined stream flow meeting the process demand rate is provided. The steam-stripped water phase removed from the base of column 22 can be neutralized by the addition of a base so that the heated water in reboiler 30 is substantially neutral. A base is introduced into line 25 by way of line 32. The addition of base through line 32 can be controlled by a pH meter 33 which senses the pH of water removed from accumulator 26 and adjusts the valve controlling the flow rate of base introduced. As set out hereinabove, a portion of the liquid accumulated in kettle 26 is removed as waste water and passed to retention zone 36 via line 27 and thence via line 52 to a conventional activated sludge unit designated generally by reference character 54. Specifically, effluent from line 52 is passed into activated sludge biotreatment tank 56 for a conventional detention time of from a few hours to a few days. Effluent from tank 56 is passed to clarifier tank 58 via line 59. (See FIG. 4). A flocculent such as alum can be added to aid in settling the solids in the clarifier and if such is used, it can be added to line 59 or directly to the clarifier. The flocculent aids in settling the solids; however, one advantage of the second embodiment of this invention is that the flocculent can be omitted because of the practice of backwashing and returning the microorganisms to the system. Sludge from clarifier tank 58 is recycled via line 62 back to tank 56; this material is primarily bacteria. Air to provide oxygen is introduced into the activated sludge tank 56 via line 60. Mixing of the air with the activated sludge is effected by stirrer 63. Water having a small amount of the microorganisms entrained therein is removed via line 64 and passed to filter 66. As shown in FIG. 1, which primarily emphasizes the first embodiment of this invention, the thus purified water is removed via line 64 and passed to filter 66. The effluent line 68 from filter 66 is divided into two lines, line 70 carrying the purified water to discharge and line 72 carrying a portion of the purified water to carbon beds 74. Effluent from carbon beds 74 is recycled by line 76 back to the biotreater. Periodically, filter 66 is backflushed so as to return any solids (predominantly bacteria) to the system so that they are not lost. Alum and other known flocculating agents can be used to accelerate sludge settling in the clarifier. As shown in FIG. 4 which primarily emphasizes the second embodiment of this invention, purified water is removed from filter 66 via line 68 and thence to line 70 carrying the purified water to discharge. Periodically pump means 75 is activated and valve 72 opened so as to pass water via line 74 to backwash filter 66 so as to return any solids (predominantly bacteria) to the system via line 76 so that they are not lost. The bacteria can be returned to the system by passing the backflush to the clarifier 58 via line 81 and valve 87 or to the biotreater 56 via valve 86. In the first instance, the biotreater is not diluted. In either case the backwashed bacteria are more susceptible to settling than they were initially. Another alternative is to pass the backwash to a surge tank or second clarifier 77 through valve 83 and then return the second clarifier sludge at a substantially constant rate to either the clarifier or biotreater and combine the separated water from this second clarifier, removed via line 78, with the purified water stream 70. Optionally a portion of the purified water from line 68 can be returned to biological treatment zone through valve 85, line 80, activated carbon filter 82 and line 84. Dilution ratios of 1:1 to 102 (feed:dilution) are satisfactory, however, one of the advantages of the second embodiment of this invention in that it is not necessary to either dilute with pure water or water treated with activated carbon to remove toxins, or otherwise pretreat the industrial waste prior to its entry into the biological treatment zone. Many conventional parts, such as temperature controllers, heating elements, valves, and the like, are not shown in the drawings for the sake of simplicity, but their inclusion is understood by those skilled in the art and is within the scope of the invention. Examples I-IV illustrate the first embodiment of this invention and Example V illustrates the second embodiment. EXAMPLE I The following runs were carried out in a 5-foot diameter, 7-foot high stainless steel tank, jacketed to permit temperature control at near 80° F. (27° C.). Air was continuously introduced through three pipes discharging just below a mixer which provided good agitation of the tank contents. Discharge liquid passed from the bottom of the tank to an adjoining clarifier consisting of a 20-inch diameter, 7-foot tall vertical tank with cone-shaped bottom. The waste water feed was derived from a butadiene plant using oxidative dehydrogenation of butenes such as shown in U.S. Pat. No. 3,646,239. Typically, the feed had an SCOD of 2240 mg/l and an SBOD of 1170 mg/l and a pH of about 3.0. Nutrients consisting of 5 parts nitrogen in the form of NH 3 and 1 part phosphorus in the form of H 3 PO 4 per 100 parts by weight of SCOD in the feed water were continuously added. Caustic soda at rates up to about 5 parts per 100 parts of SCOD was also added on an intermittent basis to control treater pH at about 7.0. Bacteria were obtained from a commercial biotreater operating in an oil refinery, using samples of recycle sludge. The bacteria were considered to be a mixed population, i.e., a mixture of strains as used in commercial biotreaters. Nalco 634, a commercial flocculating agent sold by Nalco Chemical Company was added to the clarifier to provide a concentration of 10 ppm to accelerate sludge settling. The table below compares biotreater operation with and without feed dilution: Table I______________________________________ 1:1 Ratio 1:1 Ratio Dilution Dilution With With Steam Carbon Without Con- Treated Dilution densate Effluent______________________________________Run 1 2 3Run Duration, weeks 10 6 5Feed Rate, gal/hr (m.sup.3 /day) (.95) (.55) (.55)Dilution Rate, gal/hr (m.sup.3 /day) none (.55) (.55)Residence Time in 3.0 3.0 3.0Biotreater, daysFeed Water CompositionSCOD, mg/l 2000 2100 2200SBOD, mg/l 1300 1200 1400Clarifier Effluent CompositionSCOD, mg/l 250 200** 100*SBOD, mg/l 50 35** 20*Volatile Suspended SolidsBiotreater Liquor, mg/l 4200 2400 2400→3200 (increasing)Clarifier Effluent, mg/l 50 30 45______________________________________ *Average values for last two weeks of the run. **Average values for best two weeks of the run. The dilution water of invention Run 3 was biotreated effluent which had been passed over beds of 12×40 mesh charcoal to yield water with an average COD of about 30 mg/l. The above data illustrate that operation without dilution was unable to produce specification (200 COD, 20 BOD) effluent. Dilution in 1:1 ratio with steam condensate yielded effluent essentially meeting COD specification only, but it is believed that a longer operating period would having permitted reaching the BOD specification (some mechanical problems were encountered). Operation with carbon-treated effluent yielded specification product (200 or less COD and 20 or less BOD) with respect to both COD and BOD (neglecting a small amount of insoluble material creating an oxygen demand which may be present). As can be seen, the use of carbon treated purified water from the biotreater as recycle to dilute the feed water is as effective, and apparently more effective, than utilizing steam condensate as diluent and offers a dual advantage of not requiring expensive steam and not increasing the total amount of water discharged. CALCULATED EXAMPLE II Calculated examples based on operating experience illustrates the attractiveness of the use of carbon treated recycle as compared with carbon treating biotreater feed as shown in FIGS. 2 and 3. Thus, as shown by a comparison of FIG. 2 with FIG. 3 for producing near comparable water only about 42 percent as much carbon must be regenerated for the method using carbon treatment on the recycle portion of the effluent only. Carbon makeup into the system would be proportionately less, also. It must be borne in mind that this is a comparison between the invention as exemplified by FIG. 3 and a system as exemplified by FIG. 2 which, while the control for this invention is in itself a new development which is superior to using carbon filters to treat all of the effluent. Thus, carbon treatment of a portion of the effluent which has been returned to the biotreater is superior to either carbon treatment of all of the feed or carbon treatment of all of the effluent with no recycle. EXAMPLE III The following example is designed to show that a rotating biological surface unit can also be used in accordance with this invention. The following data were obtained using a pilot sized unit containing 21 square feet (1.95 m 2 ) of surface. This surface was supplied by 18 foamed polystyrene discs 10 inches (0.254 m) in diameter which were nearly 50 percent submerged in three cells which had a total liquid volume of 8.4 l of waste water. Waste water feed was continuously supplied to the cells which were connected in series, and effluent overflowed to a collection basin. Table II______________________________________ Hydraulic LoadingLiquid Retention Dilution SCOD, mg/l GalRun Time, days Ratio Feed Effluent feed/day/ft______________________________________1 0.5 1:1 2188 188 0.1062 0.24 1:1 2256 187 0.2163 0.16 1:1 2296 226 0.334 0.32 none 2208 1488 0.33______________________________________ It is apparent that all the runs using dilution (with tap water) produced superior effluents to Run 4 which used no dilution. Runs 3 and 4 are particularly comparable since each was processing raw waste water at the same rate (same hydraulic loading), yet Run 3 yielded near specification 226 SCOD effluent for about 80 percent SCOD removal while only about 33 percent of the SCOD was removed in Run 4, made without dilution. Although the rotating biological unit was not operated with carbon treated recycle, the success of the invention as shown in Example I coupled with this data establishes that similar success would attend the rotating type of unit also. In addition, operation in accordance with the invention would have the further advantage of not increasing the amount of effluent whereas the simulated tests hereinabove did increase the amount of effluent since the tap water diluent used in these tests, of course, adds to the total discharge. EXAMPLE IV Following is a run carried out for 26 days using OXD waste water as the feed. This is essentially a duplication of Run 1, of Example I, except that it was carried out for an extended period of time. The results are shown hereinbelow in Table III wherein TOD is total oxygen demand. Total oxygen demand is determined by burning all organic matter and gives a value slightly higher than COD. TABLE III______________________________________Day Feed, TOD, mg/l Effluent, TOD, mg/l______________________________________1 1941 35734 2085 3055 2145 3256 2130 3207891011 2109 3751213 1911 4001415 1695 382161718 1815 4801920 1590 56021 1770 58222232425 1884 141026 1620 1190______________________________________ This shows that without dilution after an extended period of time the biochemical reaction is essentially killed off. The following is a run similar to Runs 1, 2 and 3 of Example III compared with a similar run wherein the effluent from the process is used for dilution. Results are given in terms of SCOD, soluble chemical oxygen demand, equal to about 90% of TOD. TABLE III______________________________________Rates SCOD, mg/l g pd/ Dilutedml/min sq.ft. of FeedRaw Raw to Bio-Run Feed Dilution Feed treater Effluent Dilution______________________________________1 40 41 0.72 1110 447 Tap water2 40 43 0.72 2216 2152 Effluent______________________________________ This shows that dilution with the effluent kills the biochemical reaction with the particular feed utilized herein. These runs are both made at a relatively high feed rate and with the feed inherently having a relatively high toxin content. Dilution with effluent can be utilized with feed water having low toxin content. The value of 2216 for the feed of the control Run 2 is simply about the same as the raw feed which has an SCOD of approximately 2200. When the effluent is first introduced as diluent, it would contain an SCOD of approximately 447 as in Run I to give a total feed SCOD of approximately 1500 based on the original feed rate but as the toxic effect of the recycle takes effect the biochemical reaction is essentially killed and the SCOD of the diluted feed approaches the SCOD of the raw feed. EXAMPLE V The following runs were carried out in a 5-foot diameter, 7-foot high stainless steel biotreater tank, jacketed to permit temperature control at near 80° F. (27° C.). Air was continuously introduced through three pipes discharging just below a mixer which provided good aeration of the tank contents for the bacterial metabolism. Discharge liquid passed from the bottom of the tank to an adjoining clarifier consisting of a 20-inch diameter, 7-foot tall vertical tank with cone-shaped bottom. The waste water feed was derived from a butadiene plant using oxidative dehydrogenation of butenes such as shown in U.S. Pat. No. 3,646,239. Typically, the feed water had a pH of about 3.0. Nutrients consisting of 5 parts nitrogen in the form of NH 3 and 1 part phosphorus in the form of H 3 PO 4 per 100 parts by weight of COD in the feed water were continuously added. Caustic soda at rates up to about 5 parts per 100 parts of COD was also added on an intermittent basis to control biotreater pH at about 7.0. Bacteria were obtained from a commercial biotreater operating in an oil refinery, using samples of recycle sludge. The bacteria were considered to be a mixed population, i.e., a mixture of strains as used in commercial biotreaters. Nalco 634, a commercial flocculating agent sold by Nalco Chemical Company was added to the clarifier to provide a concentration of 10 ppm to accelerate sludge settling. The clarifier effluent filter was a mixed media filter composed of 4-6 inches (depth) of 20-30 mesh sand and 30-36 inches of coarse anthracite coal, operated downflow. The bachwash was to the biotreater tank. The results are shown hereinbelow in Table V. TABLE V______________________________________ With Filter WithoutTest Run (Backflushed daily) Filter______________________________________Run Duration, days 40 19Retention time in biotreater,days 2.0 2.1Dilution Rate, gal/hr none noneFeed Rate, gal/hr 16.4 14.6Feed Water Composition,SCOD*, mg/l 2370 2200SBOD*, mg/l 1200 1200Clarifier Effluent Composition,SCOD, mg/l 241 400SBOD, mg/l 12 50Biotreater Solids,VSS, mg/l 3180 2800→1200SVI 83 25Clarifier Solids,TSS, mg/l 52 300Filtrate Solids,TSS, mg/l 9 --______________________________________ *The material constituting the oxygen demand is completely soluble or so nearly so that the COD and SCOD are essentially the same as are the BOD and SBOD. The additional COD and BOD imposed on the effluent by the presence of solids (microorganisms) in the clarifier effluent if it is sufficient to raise the COD and BOD (i.e. total COD and total BOD) to above acceptible standards may have to be removed, for instance, by settling but one advantage of this second embodiment of the invention is that not only does the backflush improve biotreater efficiency so that th effluent SCOD and SBOD are low but also there is less solid materials adding oxygen demand. SCOD Soluble COD SBOD Soluble BOD VSS Volatile Suspended Solids TSS Total Suspended Solids SVI Sludge Volume Index, ml of settled sludge after 30 minutes settling per gm. dry sludge. As can be seen, the use of the backwash of the invention results in improved (lower) effluent SCOD and SBOD as a result of avoiding reducing the Biotreater VSS and is easily capable of producing water meeting the requirement of 20 or less BOD. While this invention has been described in detail for the purpose of illustration, it is not to be construed as limited thereby but is intended to cover all changes and modifications within the spirit and scope thereof.
In a process for biotreating industrial waste water, a portion of the effluent is treated with activated carbon and recycled to the biotreater. This results in a substantial improvement in the biotreater performance. In another embodiment, the biotreatment is an activated sludge process and the clarifier effluent is filtered to stop loss of bacteria and periodically the filter is backwashed to return the bacteria to the system.
2
CROSS REFERENCE TO RELATED APPLICATION This application is a continuation application of U.S. patent application Ser. No. 11/544,763 filed on 10 Oct. 2006 all of which is herein incorporated by reference. FIELD OF THE INVENTION The present invention relates to the field of inkjet printers. In particular, the invention relates to inkjet printers that have printheads with a number of separate printhead integrated circuits (IC's) defining the nozzles that eject the ink or other printing fluid. CO-PENDING APPLICATIONS The following applications have been filed by the Applicant simultaneously with the present application: 11/544778 11/544779 11/544764 11/544765 11/544772 11/544773 11/544774 11/544775 11/544776 11/544766 11/544767 7384128 11/544770 11/544769 11/544777 11/544768 The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned. CROSS REFERENCES TO RELATED APPLICATIONS Various methods, systems and apparatus relating to the present invention are disclosed in the following US patents/patent applications filed by the applicant or assignee of the present invention: 6750901 6476863 6788336 7249108 6566858 6331946 6246970 6442525 7346586 09/505951 6374354 7246098 6816968 6757832 6334190 6745331 7249109 7197642 7093139 10/636263 10/636283 10/866608 7210038 10/902883 10/940653 10/942858 7364256 7258417 7293853 7328968 7270395 11/003404 11/003419 7334864 7255419 7284819 7229148 7258416 7273263 7270393 6984017 7347526 7357477 11/003463 7364255 7357476 11/003614 7284820 7341328 7246875 7322669 11/293800 11/293802 11/293801 11/293808 11/293809 11/482975 11/482970 11/482968 11/482972 11/482971 11/482969 11/246676 11/246677 11/246678 11/246679 11/246680 11/246681 11/246714 11/246713 11/246689 11/246671 11/246670 11/246669 11/246704 11/246710 11/246688 11/246716 11/246715 7367648 7370936 11/246705 11/246708 11/246693 7384119 11/246696 11/246695 11/246694 11/482958 11/482955 11/482962 11/482963 11/482956 11/482954 11/482974 11/482957 11/482987 11/482959 11/482960 11/482961 11/482964 11/482965 11/482976 11/482973 11/495815 11/495816 11/495817 6623101 6406129 6505916 6457809 6550895 6457812 7152962 6428133 7204941 7282164 10/815628 7278727 10/913373 10/913374 7367665 7138391 7153956 10/913380 10/913379 10/913376 7122076 7148345 11/172816 11/172815 11/172814 11/482990 11/482986 11/482985 11/454899 10/407212 7252366 10/683064 7360865 11/482967 11/482966 11/482988 11/482989 11/293832 11/293838 11/293825 11/293841 11/293799 11/293796 11/293797 11/293798 11/124158 11/124196 11/124199 11/124162 11/124202 11/124197 11/124154 11/124198 7284921 11/124151 11/124160 11/124192 11/124175 11/124163 11/124149 7360880 11/124173 11/124155 7236271 11/124174 11/124194 11/124164 11/124200 11/124195 11/124166 11/124150 11/124172 11/124165 11/124186 11/124185 11/124184 11/124182 11/124201 11/124171 11/124181 11/124161 11/124156 11/124191 11/124159 7370932 11/124170 11/124187 11/124189 11/124190 11/124180 11/124193 11/124183 11/124178 11/124177 11/124148 11/124168 11/124167 11/124179 11/124169 11/187976 11/188011 11/188014 11/482979 11/228540 11/228500 11/228501 11/228530 11/228490 11/228531 11/228504 11/228533 11/228502 11/228507 11/228482 11/228505 11/228497 11/228487 11/228529 11/228484 11/228489 11/228518 11/228536 11/228496 11/228488 11/228506 11/228516 11/228526 11/228539 11/228538 11/228524 11/228523 11/228519 11/228528 11/228527 11/228525 11/228520 11/228498 11/228511 11/228522 11/228515 11/228537 11/228534 11/228491 11/228499 11/228509 11/228492 11/228493 11/228510 11/228508 11/228512 11/228514 11/228494 11/228495 11/228486 11/228481 11/228477 7357311 7380709 11/228521 11/228517 11/228532 11/228513 11/228503 11/228480 11/228535 11/228478 11/228479 6238115 6386535 6398344 6612240 6752549 6805049 6971313 6899480 6860664 6925935 6966636 7024995 7284852 6926455 7056038 6869172 7021843 6988845 6964533 6981809 7284822 7258067 7322757 7222941 7284925 7278795 7249904 7152972 11/246687 11/246718 7322681 11/246686 11/246703 11/246691 11/246711 11/246690 11/246712 11/246717 11/246709 11/246700 11/246701 11/246702 11/246668 11/246697 11/246698 11/246699 11/246675 11/246674 11/246667 7156508 7159972 7083271 7165834 7080894 7201469 7090336 7156489 10/760233 10/760246 7083257 7258422 7255423 7219980 10/760253 10/760255 7367649 7118192 10/760194 7322672 7077505 7198354 7077504 10/760189 7198355 10/760232 7322676 7152959 7213906 7178901 7222938 7108353 7104629 11/446227 7370939 11/472345 11/474273 7261401 11/474279 11/482939 7328972 7322673 7303930 11/246672 11/246673 11/246683 11/246682 7246886 7128400 7108355 6991322 7287836 7118197 10/728784 7364269 7077493 6962402 10/728803 7147308 10/728779 7118198 7168790 7172270 7229155 6830318 7195342 7175261 10/773183 7108356 7118202 10/773186 7134744 10/773185 7134743 7182439 7210768 10/773187 7134745 7156484 7118201 7111926 10/773184 7018021 11/060751 11/060805 11/188017 7128402 11/298774 11/329157 11/490041 11/501767 7284839 7246885 7229156 11/505846 11/505857 7293858 7258427 11/097308 11/097309 7246876 11/097299 11/097310 7377623 7328978 7334876 7147306 11/482953 11/482977 09/575197 7079712 6825945 7330974 6813039 6987506 7038797 6980318 6816274 7102772 7350236 6681045 6728000 7173722 7088459 09/575181 7068382 7062651 6789194 6789191 6644642 6502614 6622999 6669385 6549935 6987573 6727996 6591884 6439706 6760119 7295332 6290349 6428155 6785016 6870966 6822639 6737591 7055739 7233320 6830196 6832717 6957768 09/575172 7170499 7106888 7123239 10/727181 10/727162 7377608 10/727245 7121639 7165824 7152942 10/727157 7181572 7096137 7302592 7278034 7188282 10/727159 10/727180 10/727179 10/727192 10/727274 10/727164 10/727161 10/727198 10/727158 10/754536 10/754938 10/727160 10/934720 7171323 7278697 7360131 11/488853 7328115 7369270 6795215 7070098 7154638 6805419 6859289 6977751 6398332 6394573 6622923 6747760 6921144 10/884881 7092112 7192106 11/039866 7173739 6986560 7008033 11/148237 7222780 7270391 11/478599 11/499749 11/482981 7195328 7182422 7374266 10/854522 10/854488 7281330 10/854503 7328956 10/854509 7188928 7093989 7377609 10/854495 10/854498 10/854511 10/854512 10/854525 10/854526 10/854516 7252353 10/854515 7267417 10/854505 10/854493 7275805 7314261 10/854490 7281777 7290852 10/854528 10/854523 10/854527 10/854524 10/854520 10/854514 10/854519 10/854513 10/854499 10/854501 7266661 7243193 10/854518 10/854517 10/934628 7163345 7322666 11/293804 11/293840 11/293803 11/293833 11/293834 11/293835 11/293836 11/293837 11/293792 11/293794 11/293839 11/293826 11/293829 11/293830 11/293827 11/293828 7270494 11/293823 11/293824 11/293831 11/293815 11/293819 11/293818 11/293817 11/293816 11/482978 10/760254 10/760210 7364263 7201468 7360868 10/760249 7234802 7303255 7287846 7156511 10/760264 7258432 7097291 10/760222 10/760248 7083273 7367647 7374355 10/760204 10/760205 10/760206 10/760267 10/760270 7198352 7364264 7303251 7201470 7121655 7293861 7232208 7328985 7344232 7083272 7311387 11/014764 11/014763 7331663 7360861 7328973 11/014760 11/014757 7303252 7249822 11/014762 7311382 7360860 7364257 11/014736 7350896 11/014758 7384135 7331660 11/014738 11/014737 7322684 7322685 7311381 7270405 7303268 11/014735 11/014734 11/014719 11/014750 11/014749 7249833 11/014769 11/014729 7331661 11/014733 7300140 7357492 7357493 11/014766 7380902 7284816 7284845 7255430 11/014744 7328984 7350913 7322671 7380910 11/014717 11/014716 11/014732 7347534 11/097268 11/097185 7367650 11/293820 11/293813 11/293822 11/293812 7357496 11/293814 11/293793 11/293842 11/293811 11/293807 11/293806 11/293805 11/293810 11/482982 11/482983 11/482984 11/495818 11/495819 An application has been listed by its docket number. This will be replaced when application number is known. The disclosures of these applications and patents are incorporated herein by reference. BACKGROUND OF THE INVENTION Inkjet printers eject drops of ink through an array of nozzles to effect printing on a media substrate. The nozzles are typically formed on a silicon wafer substrate using semiconductor fabrication techniques. Each nozzle is a MEMS (micro electro-mechanical systems) device driven by associated drive circuitry formed on the same silicon wafer substrate. The MEMS nozzle devices and associated drive circuitry formed on a single nozzle is commonly referred to as a printhead integrated circuit (IC). Some inkjet printheads have a single printhead IC. These are scanning type printheads that traverse back and forth across the width of a page as the printer indexes the length of the page past the printhead. The Applicant has developed a range of pagewidth printheads that have a nozzle array as long as the printing width of the page. These printheads remain stationary in the printer as the page is fed past. This allows much higher print speeds but is more complicated in terms of controlling the operation of a much larger array of nozzles. The pagewidth array of nozzles is made up of a series of separate printhead IC's placed end to end. Skilled workers in this field will appreciate that more printhead IC's can be fabricated on the unprocessed circular silicon wafers if each IC is short rather than long. Furthermore, localized fabrication defects can render an entire printhead IC defective. Hence there is less chance that each individual IC will be defective if they are shorter. The print data for each printhead IC in the pagewidth array of nozzles, is generated by another microprocessor in the printer, often referred to as a print engine controller (PEC). The PEC needs to be able to uniquely identify each of the printhead IC's so that it can send the correct print data to each nozzle. Therefore, each printhead IC has a unique address, called its write address that the PEC uses when it wants to send data to the drive circuitry on that particular IC. The Applicant has found that it is beneficial to provide the pagewidth printhead in the form of a replaceable cartridge. If nozzle clogging or actuator burn out reduce the print quality to an unacceptable level, the user simply replaces the printhead instead of the entire printer. However, user expectation demands that the printhead replacement process be as simple and failsafe as possible. Therefore, the number of interconnections between the PEC and the printhead should be minimized. When a replacement printhead is first installed, the PEC needs to interrogate the printhead IC's to determine their unique addresses so it can properly distribute the print data. This requires an electrical connection that is subsequently not used during normal operation of the printhead. SUMMARY OF THE INVENTION According to a first aspect, the present invention provides an inkjet printer comprising: a pagewidth printhead with a plurality of printhead IC's, each having an array of nozzles for ejecting drops of printing fluid onto a media substrate, and associated drive circuitry for driving the array of nozzles; a print engine controller for sending print data to the printhead IC's; an interface for electrical communication between the print engine controller and the printhead IC's; wherein, all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. Using this process, there only needs to be two electrical connections between the print engine controller and all the printhead IC's. A ‘data in’ from the PEC to the printhead IC's and a ‘data out’ line from the printhead IC's back to the PEC. According to a second aspect, the present invention provides a printhead cartridge for an inkjet printer having a PEC for sending print data to the printhead cartridge, the printhead cartridge comprising: a plurality of printhead IC's, each having an array of nozzles for ejecting drops of printing fluid onto a media substrate, the printhead IC's having a common initial address with one exception that has a different address; write address circuitry for setting the exception to the different address and providing connections between the printhead IC's so that each has its address changed from the initial address to the different address when its adjacent printhead IC has its write address changed by the PEC; and, an electrical interface for establishing two electrical connections with the PEC. Optionally, the print data signal from the PEC is multi-dropped to the printhead IC's using the unique write addresses. Optionally, the print data signal is self clocking. Optionally, the drive circuitry is configured to extract a clock signal from the data transmission from the PEC. Optionally, the data transmission is a digital signal that has a rising edge at every clock period. Optionally, the drive circuitry determines a data bit from every clock period by the position of the falling edge during that period. Optionally, the interface between the printhead and the PEC has only two connections. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In another aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. According to a second aspect, the present invention provides a printhead IC comprising: an array of nozzles; an ejection actuator corresponding to each of the nozzles respectively, the ejection actuator having a resistive heater that is activated when the actuator ejects ink through the corresponding nozzle; drive circuitry for receiving print data and activating the actuators with drive signals in accordance with the print data; and, open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. In thermal inkjet printheads and thermal bend inkjet printheads, the vast majority of failures are the result of the resistive heater burning out and breaking or ‘going open circuit’. Nozzles may fail to eject ink because of clogging but this is not a ‘dead nozzle’ and may be recovered through the printer maintenance regime. By determining which nozzles are dead with an inbuilt circuit, the print engine controller can periodically update its dead nozzle map and thereby extend to operational life of the printhead. Preferably the open actuator test circuitry generates defective nozzle feedback during print jobs. In a further preferred form the open actuator test circuitry generates defective nozzle feedback within a predetermined time period after printhead operation. In a particularly preferred form, the open actuator test circuitry generates defective nozzle feedback between each page of a print job. Preferably the drive circuitry has an actuator FET (field effect transistor) that is enabled by a drive signal to open the resistive heater to a drive voltage, and the open actuator test circuitry has NAND logic with the drive signal and an actuator test signal as inputs and outputs to the gate of the actuator FET. Preferably, the open actuator test circuitry has a sense FET with a source connected to the high voltage side of the resistive heater and a drain connected to a sense electrode, the sense FET being enabled by the test signal such that a low voltage output to the sense electrode is fed back as a functional actuator and a high voltage output to the sense electrode is fed back as a defective actuator. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the open actuator test circuitry generates defective nozzle feedback during print jobs. Optionally, the open actuator test circuitry generates defective nozzle feedback within a predetermined time period after printhead operation. Optionally, the open actuator test circuitry generates defective nozzle feedback between each page of a print job. Optionally, the drive circuitry has a drive FET controlling current to the resistive heater and logic for enabling the drive FET when a drive signal is received and disabling the drive FET when a drive signal and a open actuator test signal are received. Optionally, the drive circuitry has a bleed FET that slowly drains any voltage drop across the resistive heater to zero when the drive circuitry is not receiving a drive signal or an open actuator test signal. Optionally, the drive circuitry has a sense node between the drain of the drive FET and the resistive heater, and the open actuator test circuitry has a sense FET that is enabled when open actuator test signal is received such that the voltage at the drain of the sense FET is used to indicate whether the heater element is defective. Optionally, the drive FET is a p-type FET. Optionally, the drive circuitry receives the print data for the array in a plurality of sequential portions with a fire command at the end of each portion. In a further aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors for sensing the temperature of the printhead IC within each of the regions respectively. Optionally, the drive circuitry adjusts the drive pulses sent to the nozzles in accordance with the temperature of the printing fluid within the nozzles. Optionally, the drive circuitry blocks the dive pulses sent to at least some of the nozzles in the array when one or more of the temperature sensors indicate the temperature exceeds a predetermined maximum. Optionally, the drive pulses consist of ejection pulses with sufficient energy to eject printing fluid from the nozzles designated to fire at that time, and sub-ejection pulses with insufficient energy to eject printing fluid from the nozzles not designated to fire at that time. Optionally, during use the drive circuitry adjusts the drive pulse profile in response to the temperature sensor output. Optionally, during use, the temperature sensor can be de-activated after a period of use. Optionally, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, each row of nozzles is divided into a plurality of groups, each having at least one nozzle the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, during use the drive circuitry actuates the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession such that, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. According to a third aspect, the present invention provides a printhead IC comprising: an array of nozzles; drive circuitry for receiving print data and fire commands from a print engine controller; wherein during use, the drive circuitry receives the print data for the array in a plurality of sequential portions with a fire command at the end of each portion. Instead of providing a shift register for each nozzle in the array, the printhead IC only has enough dot data shift registers for a portion of the nozzle array which it fires while the shift register load with the dot data for the next portion of the array. This moves the shift register out of the unit cell (the smallest repeating unit of nozzles and corresponding ink chamber, actuator and drive circuitry) which allows the drive FET to be larger while not impacting on the nozzle density. As discussed above, a larger drive FET can generate a drive pulse at higher power levels for more efficient drop ejection. Preferably, the array is configured into rows and columns, and the sequential portions are the nozzles in each individual row such that the rows eject printing fluid one row at a time. In a further preferred form, the drive circuitry is configured to fire the rows in a predetermined sequence and the print engine controller sends the print data for each row to the drive circuitry in the predetermined sequence. In a particularly preferred form, the print data for the next row in the predetermined sequence is loaded as the previous row is fired. Preferably, the nozzles in each of the rows eject the same type of printing fluid. Optionally, the array is configured into rows and columns, and the sequential portions are the nozzles in each individual row such that the rows eject printing fluid one row at a time. Optionally, the drive circuitry is configured to fire the rows in a predetermined sequence and the print engine controller sends the print data for each row to the drive circuitry in the predetermined sequence. Optionally, the print data for the next row in the predetermined sequence is loaded as the previous row is fired. Optionally, the nozzles in each of the rows eject the same type of printing fluid. In a further aspect there is provided a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the open actuator test circuitry generates defective nozzle feedback during print jobs. In a further aspect there is provided a printhead IC according further comprising a plurality of temperature sensors for sensing the temperature of the printhead IC within each of the regions respectively. Optionally, the drive circuitry adjusts the drive pulses sent to the nozzles in accordance with the temperature of the printing fluid within the nozzles. Optionally, the drive circuitry blocks the dive pulses sent to at least some of the nozzles in the array when one or more of the temperature sensors indicate the temperature exceeds a predetermined maximum. Optionally, the drive pulses consist of ejection pulses with sufficient energy to eject printing fluid from the nozzles designated to fire at that time, and sub-ejection pulses with insufficient energy to eject printing fluid from the nozzles not designated to fire at that time. Optionally, during use the drive circuitry adjusts the drive pulse profile in response to the temperature sensor output. Optionally, during use, the temperature sensor can be de-activated after a period of use. Optionally, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, each row of nozzles is divided into a plurality of groups, each having at least one nozzle the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, during use the drive circuitry actuates the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession such that, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a fourth aspect, the present invention provides a printhead IC comprising: an array of nozzles having a plurality of adjacent regions; and, drive circuitry for sending an electrical pulse to each of the nozzles individually such that they eject a drop of printing fluid; and, a plurality of temperature sensors for sensing the temperature of the printhead IC within each of the regions respectively. Monitoring the temperature across the printhead IC with several sensors gives the drive circuitry a temperature profile of the ink in different regions. Using the feedback from the sensors, the drive pulse sent to the nozzles in each region can be adjusted to best suit the current viscosity of the ink. By compensating for any ink viscosity differences, the drop ejection characteristics are kept uniform across the entire printhead IC, and thereby the whole pagewidth printhead. As discussed above, uniform drop ejection improves the print quality. Preferably, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the electrical pulses sent to the nozzles in the region currently operating in that temperature zone. In a further preferred form the pulse profile for each temperature zone differs in its duration. In a particularly preferred form, the associated drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. In some embodiments, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. In specific forms of this embodiment, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. In some versions of this embodiment, the associated drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the electrical pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the open actuator test circuitry generates defective nozzle feedback during print jobs. In a further aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. Optionally, the drive circuitry adjusts the drive pulses sent to the nozzles in accordance with the temperature of the printing fluid within the nozzles. Optionally, the drive circuitry blocks the dive pulses sent to at least some of the nozzles in the array when one or more of the temperature sensors indicate the temperature exceeds a predetermined maximum. Optionally, the drive pulses consist of ejection pulses with sufficient energy to eject printing fluid from the nozzles designated to fire at that time, and sub-ejection pulses with insufficient energy to eject printing fluid from the nozzles not designated to fire at that time. Optionally, during use the drive circuitry adjusts the drive pulse profile in response to the temperature sensor output. Optionally, during use, the temperature sensor can be de-activated after a period of use. Optionally, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, each row of nozzles is divided into a plurality of groups, each having at least one nozzle the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, during use the drive circuitry actuates the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession such that, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a fifth aspect, the present invention provides a printhead IC comprising: an array of nozzles; and, drive circuitry for sending an drive pulse to each of the nozzles individually such that they eject a drop of printing fluid; wherein, the drive circuitry adjusts the drive pulses sent to the nozzles in accordance with the temperature of the printing fluid within the nozzles. Monitoring the temperature of individual printhead IC's allows the drive circuitry to compensate for any differences in ink viscosity between different printhead IC's of the pagewidth printhead. By compensating for any ink viscosity differences, the drop ejection characteristics are kept uniform across the entire printhead to improve the print quality. Preferably, the printhead IC further comprises a plurality of temperature sensors, each for sensing the temperature the nozzles within a region of the array such that the drive pulse for the nozzles in one region differs from the drive pulse for the nozzles in another region in response to a temperature difference between the regions. Preferably, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. In a further preferred form the pulse profile for each temperature zone differs in its duration. In a particularly preferred form, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. In some embodiments, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. In specific forms of this embodiment, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. In some versions of this embodiment, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In a further aspect the present invention provides a printhead IC further comprises a plurality of temperature sensors, each for sensing the temperature the nozzles within a region of the array such that the drive pulse for the nozzles in one region differs from the drive pulse for the nozzles in another region in response to a temperature difference between the regions. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In a further aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In a further aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, the drive circuitry blocks the drive pulses sent to at least some of the nozzles in the array when one or more of the temperature sensors indicate the temperature exceeds a predetermined maximum. Optionally, the drive pulses consist of ejection pulses with sufficient energy to eject printing fluid from the nozzles designated to fire at that time, and sub-ejection pulses with insufficient energy to eject printing fluid from the nozzles not designated to fire at that time. Optionally, during use the drive circuitry adjusts the drive pulse profile in response to the temperature sensor output. Optionally, during use, the temperature sensor can be de-activated after a period of use. Optionally, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, each row of nozzles is divided into a plurality of groups, each having at least one nozzle the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, during use the drive circuitry actuates the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession such that, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a sixth aspect, the present invention provides a printhead IC comprising: an array of nozzles; and, drive circuitry for sending an drive pulse to each of the nozzles individually such that they eject a drop of printing fluid; and, a temperature sensor for sensing the temperature of printing fluid within the array; wherein, the drive circuitry blocks the drive pulses sent to at least some of the nozzles in the array when the sensor indicates the temperature exceeds a predetermined maximum. De-activating the heaters at a maximum temperature effectively aborts the print job but prevents nozzle burn-out. An overheating safeguard allows the nozzles to be recovered when the problem has been remedied. Preferably, the drive circuitry reduces the duration the drive pulses as the temperatures of the printing fluid approaches the predetermined maximum such that the direction at the predetermined maximum is zero. Monitoring the temperature of individual printhead IC's allows the drive circuitry to compensate for any differences in ink viscosity between different printhead IC's of the pagewidth printhead. By compensating for any ink viscosity differences, the drop ejection characteristics are kept uniform across the entire printhead to improve the print quality. Preferably, the printhead IC further comprises a plurality of temperature sensors, each for sensing the temperature the nozzles within a region of the array such that the drive pulse for the nozzles in one region differs from the drive pulse for the nozzles in another region in response to a temperature difference between the regions. Preferably, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. In some embodiments, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. In specific forms of this embodiment, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. In some versions of this embodiment, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the drive circuitry reduces the duration the drive pulses as the temperatures of the printing fluid approaches the predetermined maximum such that the direction at the predetermined maximum is zero. In a further aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors, each for sensing the temperature the nozzles within a region of the array such that the drive pulse for the nozzles in one region differs from the drive pulse for the nozzles in another region in response to a temperature difference between the regions. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In a further aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In a further aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive pulses consist of ejection pulses with sufficient energy to eject printing fluid from the nozzles designated to fire at that time, and sub-ejection pulses with insufficient energy to eject printing fluid from the nozzles not designated to fire at that time. Optionally, during use the drive circuitry adjusts the drive pulse profile in response to the temperature sensor output. Optionally, during use, the temperature sensor can be de-activated after a period of use. Optionally, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, each row of nozzles is divided into a plurality of groups, each having at least one nozzle the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, during use the drive circuitry actuates the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession such that, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a seventh aspect, the present invention provides a printhead IC comprising: an array of nozzles; and, drive circuitry for receiving print data and sending drive pulses to the nozzles in accordance with the print data; wherein, the drive pulses consist of ejection pulses with sufficient energy to eject printing fluid from the nozzles designated to fire at that time, and sub-ejection pulses with insufficient energy to eject printing fluid from the nozzles not designated to fire at that time. The drive circuitry sends an drive pulse to every nozzle in the array regardless of whether the print data has designated it to be a firing nozzle at that time. The non-firing nozzles are sent a sub-ejection pulse that is not enough to eject a drop of ink, but does maintain the temperature of the ink at the nozzle so that when next it fires, its ink temperature, and hence viscosity, is similar to that of the more frequently firing nozzles. Preferably, the sub-ejection pulses have the same voltage and current as the ejection pulses, but a shorter duration. In a further preferred form, printhead IC further comprises a temperature sensor that has an output indicative of the temperature of at least part of the array wherein the drive circuitry sets the duration of the drive pulses to zero if the temperature sensor indicates that the temperature is above a predetermined maximum. Preferably, the printhead IC further comprises a plurality of temperature sensors, each for sensing the temperature the nozzles within a region of the array such that the drive pulse for the nozzles in one region differs from the drive pulse for the nozzles in another region in response to a temperature difference between the regions. Preferably, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Monitoring the temperature of individual printhead IC's allows the drive circuitry to compensate for any differences in ink viscosity between different printhead IC's of the pagewidth printhead. By compensating for any ink viscosity differences, the drop ejection characteristics are kept uniform across the entire printhead to improve the print quality. In some embodiments, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. In specific forms of this embodiment, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the sub-ejection pulses have the same voltage and current as the ejection pulses, but a shorter duration. In a further aspect the present invention provides a printhead IC further comprising a temperature sensor that has an output indicative of the temperature of at least part of the array wherein the drive circuitry sets the duration of the drive pulses to zero if the temperature sensor indicates that the temperature is above a predetermined maximum. In a further aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors, each for sensing the temperature the nozzles within a region of the array such that the drive pulse for the nozzles in one region differs from the drive pulse for the nozzles in another region in response to a temperature difference between the regions. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. In a further aspect the present invention provides a printhead IC further comprising the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In a further aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In a further aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry adjusts the drive pulses sent to the nozzles in accordance with the temperature of the printing fluid within the nozzles. Optionally, during use the drive circuitry adjusts the drive pulse profile in response to the temperature sensor output. Optionally, during use, the temperature sensor can be de-activated after a period of use. Optionally, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, each row of nozzles is divided into a plurality of groups, each having at least one nozzle the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. Optionally, during use the drive circuitry actuates the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession such that, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to an eighth aspect, the present invention provides a printhead IC comprising: an array of nozzles; associated drive circuitry for receiving print data and sending drive pulses of electrical energy to the array of nozzles in accordance with the print data; and, a temperature sensor connected to the drive circuitry to adjust the drive pulse profile in response to the temperature sensor output; wherein during use, the temperature sensor can be de-activated after a period of use. A temperature sensor on each printhead IC allows the drive circuitry to adjust the drive pulses to compensate for temperature variations. However, the temperature sensor is an added power load and an additional electronic component that generates noise in the other circuits. By de-activating the sensor once the operating temperature is known, the power and noise problems created by the sensor are temporary. The temperature of the printhead IC is not likely to vary rapidly or by large amounts once it has reached its operating temperature, so it can be de-activated with a good probability that any temperature compensation to the drive pulse profile will remain correct. Preferably, the temperature sensor periodically re-activates such that the drive circuitry can adjust the drive pulse profile if necessary. In a further preferred form, the printhead IC has a plurality of temperature sensors spaced along the array, wherein during use, one or more of the temperature sensors can be de-activated. In some embodiments, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Preferably, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. In one embodiment, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Preferably, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. In a further preferred form the pulse profile for each temperature zone differs in its duration. In a particularly preferred form, the associated drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. In some embodiments, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. In specific forms of this embodiment, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. In some versions of this embodiment, the associated drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the temperature sensor periodically re-activates such that the drive circuitry can adjust the drive pulse profile if necessary. In a further aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors spaced along the array, wherein during use, one or more of the temperature sensors can be de-activated. Optionally, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In a further aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In a further aspect the present invention provides a printhead IC comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a ninth aspect, the present invention provides an inkjet printer comprising: an array of nozzles arranged into rows, each row of nozzles is divided into a plurality of groups, each having at least one nozzle; and, drive circuitry for sending a drive pulse to each of the nozzles individually such that they eject a drop of printing fluid; wherein, the drive circuitry delays sending the drive pulses to one of the groups relative to at least one of the other groups. By firing the nozzles in stages, the rate of change of the current drawn from the power supply decreases. This in turn lowers the impedance in the circuit and therefore, the voltage sag. The minimum time available to fire all the nozzles in arrow is set by the ink refill time. In the Applicant's printhead IC designs, the ink refill can be approximately 50 microseconds. The duration of the firing pulse is about 300 to 500 nanoseconds. In a printhead IC with, say, ten rows of nozzles, each row has about 5 microseconds to fire all the nozzles. To fire the row in less time is possible but would mean the row would spend some time completely inactive in between row fires. The invention utilizes this time to stagger the nozzle firing sequence in the row and thereby smooth the increase in the current required. Preferably, the row of nozzles is made up of a series of regions, and the sets are determined by the nozzles that are positioned within one of the regions. In a further preferred form, each row has a total time available for it to eject printing fluid from all the nozzles, and the drive pulse sent to eject printing fluid from the nozzles in one region, partially overlaps with the drive pulse sent to eject printing fluid from the nozzles of at least one other region. Optionally, the array is made up of a series of regions, with a number of the groups from each row being within each of the regions, such that the drive circuitry starts sending the drive pulses to each of the regions sequentially. Optionally, the drive pulses are sent to each region in a firing sequence such that only one nozzle from each group fires simultaneously, and the firing sequence for each region having the same duration such that the firing sequence from the one region, partially overlaps with more than of the firing sequences from other regions in the same row. In a further aspect the present invention provides an inkjet printer comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the array of nozzles and the drive circuitry is fabricated on a printhead IC, the printhead IC being mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In a further aspect the present invention provides an inkjet printer further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a tenth aspect, the present invention provides an inkjet printer comprising: an array of nozzles arranged into rows, each row consisting of a plurality of nozzle groups, the nozzles in each group being interspersed with nozzles from the other groups; and, associated drive circuitry for actuating the nozzles in the row in accordance with a firing sequence, the firing sequence enabling the nozzles in each group to eject printing fluid simultaneously, and enabling each of the groups to eject printing fluid in succession; wherein, the nozzles in each group are spaced from each other by at least a predetermined minimum number of nozzles and, each of the nozzles in a group is spaced from the nozzles in the subsequently enabled group by at least the predetermined minimum number of nozzles. The invention sets the nozzle firing sequence in each row such that the nozzles fire in staggered groups, the nozzles within each group can be selected so that they are not too close to a simultaneously fired nozzle, or a nozzle that is fired immediately afterwards. Staging the nozzle firings avoids the high current required for firing the whole row simultaneously. Maintaining a minimum spacing between simultaneously fired nozzles and the nozzles fired immediately after them avoids the detrimental effects of fluidic cross talk and aerodynamic interference. It should be noted that the print data is unlikely to require every nozzle in a row to fire in the same firing sequence. However, the invention enables every nozzle to fire at a certain time within the firing sequence, regardless of whether it does fire a drop. Therefore, the spacing between simultaneously firing nozzles, or sequentially firing nozzles, will often be more than the predetermined minimum spacing, but this is not detrimental to the print quality. The invention is concerned with ensuring the spacing between two potentially interfering drops is never less than the predetermined minimum. Preferably, the row is divided into spans having only one nozzle from every group so that the number of spans across the row equals the number of groups of nozzles. In a further preferred form, the predetermined minimum number of nozzles between sequentially enabled nozzles is a uniform shift along each span in a uniform direction, the shift being a number of nozzles that is an integer greater than one and not a factor of the number of nozzles in the span, such that, the successively enabled nozzles in each span progress toward one end of the span until there are insufficient nozzles left at the end to fill the shift, in which case, the shift is completed with nozzles at the opposite end of the span so that all the nozzles in the span are enabled once during the firing sequence. In a particularly preferred form, the shift is the number of nozzles that is the nearest integer to the square root of the span, that is not a factor (i.e. the span can not be divisible by the shift without a remainder). The Applicant has found that this provides a maximum spacing in time and space for ejected drops. Optionally, the row is divided into spans having only one nozzle from every group so that the number of spans across the row equals the number of groups of nozzles. Optionally, the predetermined minimum number of nozzles between sequentially enabled nozzles is a uniform shift along each span in a uniform direction, the shift being a number of nozzles that is an integer greater than one and not a factor of the number of nozzles in the span, such that, the successively enabled nozzles in each span progress toward one end of the span until there are insufficient nozzles left at the end to fill the shift, in which case, the shift is completed with nozzles at the opposite end of the span so that all the nozzles in the span are enabled once during the firing sequence. Optionally, the shift is the number of nozzles that is the nearest integer to the square root of the span, that is not a factor. In a another aspect the present invention provides an inkjet printer further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In a further aspect the present invention provides an inkjet printer mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In a further aspect the present invention provides an inkjet printer further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to an eleventh aspect, the present invention provides a printhead IC for an inkjet printer that mounts the printhead IC together with at least one other like printhead IC to provide a pagewidth printhead for printing onto a media substrate fed past the printhead in a feed direction, the printhead IC comprising: an elongate array of nozzles, the nozzles arranged into rows, at least one of the rows having a first section positioned on a line extending perpendicular to the feed direction, a second section positioned along a parallel line displaced from the first section, and an intermediate section of nozzles extending between the first section and the second section; and, a supply conduit for providing printing fluid to the first section, the second section and the intermediate section, the supply conduit having a first portion extending perpendicular to the feed direction for supplying the first section of nozzles, a second portion extending perpendicular to the feed direction for supplying the second section of nozzles and an inclined portion for supplying the intermediate section of nozzles. Inclining a section of the nozzle rows down to meet the drop triangle, avoids sharp corners in the corresponding supply conduit. Preferably, the intermediate section of nozzles follows a stepped path from the first section to the section. In a further preferred form the stepped path comprises steps of two nozzles each, the two nozzles on each step being positioned on a line extending perpendicular to the feed direction. In a particularly preferred form each of the rows in the array have a first and second section extending perpendicular to the feed direction and an inclined section extending between the two. In some embodiments, the array of nozzles are fabricated on one side of a wafer substrate and the supply conduits are a series of channels etched into the opposite side of the wafer substrate. In specific embodiments, each of the supply conduits supplies printing fluid to two of the rows of nozzles. Optionally, the intermediate section of nozzles follows a stepped path from the first section to the section. Optionally, the stepped path comprises steps of two nozzles each, the two nozzles on each step being positioned on a line extending perpendicular to the feed direction. Optionally, the array of nozzles are fabricated on one side of a wafer substrate and the supply conduits are a series of channels etched into the opposite side of the wafer substrate. Optionally, each of the supply conduits supplies printing fluid to two of the rows of nozzles. Optionally, the nozzles eject printing fluid in accordance with print data from a print engine controller, the printing fluid ejected from the intermediate section is progressively delayed with each step on the stepped path. In another aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In another aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In another aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. According to a twelfth aspect, the present invention provides a printhead IC comprising: an array of nozzles, each with a corresponding heater to form a vapor bubble in printing fluid that causes a drop of the printing fluid to eject through the nozzle; and, drive circuitry for generating drive pulses that energize the heaters, the drive circuitry being configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses; wherein, the de-clog pulse has a longer duration than the printing pulse. The bubble formed by a relatively long, low power pulse is a larger bubble. A larger bubble imparts a greater impulse to the ink and is therefore better able to de-clog the nozzle. The impulse is the pressure integrated over the bubble area and the pulse duration. During the printing mode, it is desirable to nucleate the bubble quickly to reduce the heat lost into the ink by conduction as the heater heats up to the superheated temperature. By lowering the pulse power, bubble nucleation is delayed. During the delay, the heater increases the heat conducted into the ink. The thermal energy of the ink rises and upon nucleation, the stored energy is released as a larger bubble with greater impulse. Optionally, the de-clog pulse is preceded by a series of sub-ejection pulses that do not have sufficient energy to nucleate a bubble in the printing fluid. Optionally, the drive circuitry sends de-clog pulses to at least some of the nozzles during a print job. Optionally, the drive circuitry sends the de-clog pulses between pages of the print job. In another aspect the present invention provides an inkjet printer further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the array is arranged into rows and columns of nozzles and each of the regions are a plurality of adjacent columns, such that the drive circuitry is configured to fire the nozzles one row at a time. Optionally, the drive circuitry enables the nozzles in the row to fire in a predetermined firing sequence. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. Optionally, the array of nozzles and the drive circuitry is fabricated on a printhead IC, the printhead IC being mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In another aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry extracts a clock signal from the print data transmission from the PEC. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a thirteenth aspect, the present invention provides a printhead IC for an inkjet printer, the inkjet printer having a PEC for sending print data to the printhead IC, the printhead IC comprising: an array of nozzles for ejecting drops of printing fluid onto a media substrate; and, drive circuitry for driving the array of nozzles, the drive circuitry being configured to extract a clock signal from the data transmission from the PEC. By incorporating a clocking signal into the print data signal, the number of connections between the PEC and the printhead IC's. This is particularly beneficial if the pagewidth printhead is provided as a replaceable cartridge as the electrical interface that the cartridge mates with upon insertion has less contacts and therefore easier to install. Giving all the printhead IC's a write address and daisy-chaining the IC's together via their data outputs, allows the PEC to have a single data in line and a single data out line. In this case the electrical interface only has two contacts. By initializing the printhead IC's in response to power up, the PEC/printhead IC's interface does not need a separate reset line connected to each of the IC's. In fact, the PEC can have as little as two electrical connections. There is no need to initialize the printhead IC's using. A ‘data in’ from the PEC to the printhead IC's and a ‘data out’ line from the printhead IC's back to the PEC are the only connections required if the print data is sent via a self clocking data signal. If the data in signal is not self clocking, it will need to have a clock line through the PEC/printhead IC interface. Optionally, the data transmission is a digital signal that has a rising edge at every clock period. Optionally, the drive circuitry determines a data bit from every clock period by the position of the falling edge during that period. In another aspect the present invention provides a printhead IC linked with other like printhead IC's to form a pagewidth printhead, wherein the data transmission is multi-dropped to all the printhead IC's and each printhead IC has a unique write address provided by the PEC. Optionally, the interface between the printhead and the PEC has only two connections. In another aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In another aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In another aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the drive circuitry resets itself to a known initial state in response to receiving power from a power source after a period of not receiving power from the power source. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a fourteenth aspect, the present invention provides a printhead IC for an inkjet printer, the inkjet printer having a PEC for sending print data to the printhead IC, the printhead IC comprising: an array of nozzles for ejecting drops of printing fluid onto a media substrate; and, drive circuitry for driving the array of nozzles, the drive circuitry being configured for connection to a power source in the printer; wherein, the drive circuitry being configured to reset itself to a known initial state in response to receiving power from the power source after a period of not receiving power from the power source. By initializing the printhead IC's in response to power up, the PEC/printhead IC's interface does not need a separate reset line connected to each of the IC's. In fact, the PEC can have as little as two electrical connections. There is no need to initialize the printhead IC's using. A ‘data in’ from the PEC to the printhead IC's and a ‘data out’ line from the printhead IC's back to the PEC are the only connections required if the print data is sent via a self clocking data signal. If the data in signal is not self clocking, it will need to have a clock line through the PEC/printhead IC interface. Optionally, the drive circuitry is configured to extract a clock signal from the data transmission from the PEC. Optionally, the data transmission is a digital signal that has a rising edge at every clock period. Optionally, the drive circuitry determines a data bit from every clock period by the position of the falling edge during that period. In another aspect the present invention provides a printhead IC linked with other like printhead IC's to form a pagewidth printhead, wherein the data transmission is multi-dropped to all the printhead IC's and each printhead IC has a unique write address provided by the PEC. In another aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, each of the plurality of temperature sensors is activated sequentially for a period of time during the print job. Optionally, the plurality of temperatures sensors are divided into two or more groups, each group being activated for a sensing period in accordance with a predetermined repeating sequence for the duration of a print job. Optionally, each of the plurality of temperature sensors, is configured to sense the temperature a corresponding region of the array such that the drive pulse for the nozzles in one region can differs from the drive pulse for the nozzles in another region. Optionally, every second temperature sensor in the plurality of temperature sensors is de-activated such that the drive circuitry adjusts the drive pulse profile for the region corresponding to each activated temperature sensor and applies the same adjustment to the adjacent region where the temperature sensor is de-activated. Optionally, the drive circuitry is programmed with a series of temperature thresholds defining a set of temperature zones, each of the zones having a different pulse profile for the drive pulses sent to the nozzles in the region currently operating in that temperature zone. Optionally, the pulse profile for each temperature zone differs in its duration. Optionally, the drive circuitry sets the pulse duration to zero if the temperature sensor indicates that region is operating at a temperature above the highest of the temperature thresholds. Optionally, the drive circuitry sets the duration of the pulse profile to a sub ejection value for any of the nozzles in the row that are not to eject a drop during that firing sequence. In another aspect the present invention provides a printhead IC mounted to a pagewidth printhead with a plurality of like printhead IC's, wherein all the printhead IC's have a common initial address with one exception, the exception having a different address such that the print engine controller sends a first instruction to any printhead IC's having the different address, the first broadcast instruction instructing the printhead IC having the different address to change its address to a first unique address, the printhead IC's being connected to each other such that once the exception has changed its address to the first unique address, it causes one of the printhead IC's having a common address to change its address to the different address, so that when the print engine controller sends a second broadcast instruction to the different address, the printhead IC with the different address changes its address to a second unique address as well as causing one of the remaining printhead IC's having the common address to change to a different address, the process repeating until the print engine controller assigns the printhead IC's with mutually unique addresses. In another aspect the present invention provides a printhead IC comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. Optionally, the interface between the printhead and the PEC has only two connections. Optionally, the drive circuitry is configured to receive the print data in any one of a plurality of different data transmission protocols. According to a fifteenth aspect, the present invention provides a printhead IC for an inkjet printer, the inkjet printer having a PEC for sending print data to the printhead IC in accordance with a predetermined data transmission protocol, the printhead IC comprising: an array of nozzles for ejecting drops of printing fluid onto a media substrate; and, drive circuitry for driving the array of nozzles; wherein, the circuitry is configured to receive print data in any one of a plurality of different data transmission protocols. Making the printhead IC's compatible with different data transmission protocols increases the versatility of the printhead IC design. A versatile design lowers the types of chip that need to be fabricated thereby lowering production costs. Optionally, one of the data transmission protocols is a self clocking data signal and another data transmission protocol has separate clock and data signals. Optionally, connection to a power source within the printer, the drive circuitry cycles through different operating modes until it aligns with the data transmission protocol being used by the PEC. Optionally, the drive circuitry is configured to extract a clock signal from the data transmission from the PEC. Optionally, the data transmission is a digital signal that has a rising edge at every clock period. Optionally, the drive circuitry determines a data bit from every clock period by the position of the falling edge during that period. In another aspect the present invention provides a printhead IC linked with other like printhead IC's to form a pagewidth printhead, wherein the data transmission is multi-dropped to all the printhead IC's and each printhead IC has a unique write address provided by the PEC. Optionally, the interface between the printhead and the PEC has only two connections. In another aspect the present invention provides a printhead IC further comprising open actuator test circuitry for selectively disabling the actuators when they receive a drive signal while comparing the resistance of the resistive heater to a predetermined threshold to assess whether the actuator is defective. Optionally, during use feedback from the open actuator test circuitry is used to adjust the print data subsequently received by the drive circuitry. Optionally, the open actuator test circuitry generates defective nozzle feedback during print jobs. Optionally, the open actuator test circuitry generates defective nozzle feedback within a predetermined time period after printhead operation. Optionally, the drive circuitry has a drive FET controlling current to the resistive heater and logic for enabling the drive FET when a drive signal is received and disabling the drive FET when a drive signal and a open actuator test signal are received. Optionally, the drive circuitry has a bleed FET that slowly drains any voltage drop across the resistive heater to zero when the drive circuitry is not receiving a drive signal or an open actuator test signal. Optionally, the drive circuitry has a sense node between the drain of the drive FET and the resistive heater, and the open actuator test circuitry has a sense FET that is enabled when open actuator test signal is received such that the voltage at the drain of the sense FET is used to indicate whether the heater element is defective. Optionally, the drive FET is a p-type FET. Optionally, the drive circuitry receives the print data for the array in a plurality of sequential portions with a fire command at the end of each portion. In another aspect the present invention provides a printhead IC further comprising a plurality of temperature sensors positioned along the array of nozzles such that the drive circuitry adjusts the drive pulses in response to the temperature sensor outputs. Optionally, the drive circuitry blocks the dive pulses sent to at least some of the nozzles in the array when one or more of the temperature sensors indicate the temperature exceeds a predetermined maximum. Optionally, the drive circuitry is configured to operate in two modes, a printing mode in which the drive pulses it generates are printing pulses, and a maintenance mode in which the drive pulses are de-clog pulses, such that, the de-clog pulse has a longer duration than the printing pulse. BRIEF DESCRIPTION OF THE DRAWINGS Specific embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: FIG. 1 is a schematic representation of the linking printhead IC construction; FIG. 2 is a schematic representation of the unit cell; FIG. 3 shows the configuration of the nozzle array on a printhead IC; FIG. 4 is a schematic representation of the column and row positioning of the nozzles in the array; FIG. 5A is a schematic representation of the non-distorted array of nozzles; FIG. 5B is a schematic representation of the distortion of the array for continuity with adjacent printhead IC's; FIG. 5C is an enlarged view of the sloped section of the array with the ink supply channels overlaid; FIG. 6A shows the prior art configuration of a linking printhead IC with drop triangle; FIG. 6B shows the ink supply channels corresponding to the nozzle array shown in FIG. 6A ; FIG. 7 is a schematic representation of the printhead connection to SoPEC; FIG. 8 is a schematic representation of the printhead connection to MoPEC; FIG. 9 show self clocking data signals for a ‘1’ bit and a ‘0’ bit; FIG. 10 shows a sketch of the eight TCPG regions across an Udon IC; FIG. 11 is a sketch of the two nozzle rows firing in sequences defined by different span and shifts; FIG. 12 is a schematic representation of the firing sequence of a nozzle row segment with a span of five and a shift of three; FIG. 13A the current drawn over one row time for each TCPG region and the total row during a uniformly initiated region firing sequence; FIG. 13B is the current drawn over one row time for each TCPG region and the total row during a delayed region firing sequence; FIG. 14 is the dot data loading and row firing sequence for a ten row Udon IC; FIG. 15 shows the drop triangle and sloping segment of a nozzle row together with the relevant printing delay for the dot data at the ‘dropped’ nozzles; FIG. 16 shows de-clog pulse train; FIG. 17A is the circuitry for the Open Actuator Test in a unit cell with p-type drive FET; and, FIG. 17B is the circuitry for the Open Actuator Test in a unit cell with n-type drive FET. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The Applicant has developed a range of printhead devices that use a series of printhead integrated circuits (ICs) that link together to form a pagewidth printhead. In this way, the printhead IC's can be assembled into printheads used in applications ranging from wide format printing to cameras and cellphones with inbuilt printers. One of the more recent printhead IC's developed by the Applicant is referred to internally as wide range of printing applications. The Applicant refers to these printhead IC's as ‘Udon’ and the various aspects of the invention will be described with particular reference to these printhead IC's. However, it will be appreciated that this is purely for the purposes of illustration and in no way limiting to the scope and application of the invention. Overview The Udon printhead IC is designed to work with other Udon ICs to make a linking printhead. The Applicant has developed a range of linking printheads in which a series of the printhead IC's are mounted end-to-end on a support member to form a pagewidth printhead. The support member mounts the printhead IC's in the printer and also distributes ink to the individual IC's. An example of this type of printhead is described in U.S. Ser. No. 11/293,820, the disclosure of which is incorporated herein by cross reference. It will be appreciated that any reference to the term ‘ink’ is to be interpreted as any printing fluid unless it is clear from the context that it is only a colorant for imaging print media. The printhead IC's can equally eject invisible inks, adhesives, medicaments or other functionalized fluids. FIG. 1 shows a sketch of a pagewidth printhead 10 with the series of Udon printhead ICs 12 mounted to a support member 14 . The angled sides 16 allow the nozzles from one of the IC's 12 overlap with those of an adjacent IC in the paper feed direction 18 . Overlapping the nozzles in each IC 12 provides continuous printing across the junction between two IC's. This avoids any ‘banding’ in the resulting print. Linking individual printhead IC's in this manner allows printheads of any desired length to be made by simply using different numbers of IC's. The printhead IC's 12 are integrated CMOS and MEMS ‘chips’. FIG. 3 shows the configuration of MEMS nozzles 20 on the ink ejection side of the printhead IC 12 . The nozzles 20 are arranged into rows 26 and columns 24 to form a parallelogram array 22 with ‘kinked’ or inclined portion 28 . The columns 24 are not aligned with the paper feed direction 18 because the sides of the array 22 are angled approximately 45° for the purposes of linking with adjacent IC's. The columns 24 follow this incline. The rows 26 are perpendicular to the paper feed direction except for a sloped section 28 inclined towards a ‘drop triangle’ 30 which has the nozzles 20 that overlap the adjacent printhead IC. This is discussed in more detail below. FIG. 2 shows the elements of a single MEMS nozzle device 20 or ‘unit cell’. The construction of the unit cell 20 is discussed in detail in U.S. Ser. No. 11/246,687, the contents of which is incorporated herein by cross reference. Briefly, FIG. 2 shows the unit cell as if the nozzle plate (the outer surface of the printhead) were transparent to expose the interior features. The nozzle 32 is the ejection aperture through which the ink is ejected. The heater 34 is positioned in the nozzle chamber 36 to generate a vapour bubble that ejects a drop of ink through the nozzle 32 . The U-shaped sidewall 38 defines the edges of the chamber 36 . Ink enters the chamber 36 through the inlet 42 which has two rows of column features 44 that baffle pressure pulses in the ink to stop cross talk between unit cells. The CMOS layer defines the drive circuitry and has a drive FET 40 for the heater 34 and logic 46 for pulse timing and profiling. This is discussed in more detail below. Ink is supplied to the unit cells 20 from channels in the opposite side of the wafer substrate of the printhead IC. These are described below with reference to FIG. 5C . The channels in the ‘back side’ of the printhead IC 12 are in fluid communication with the unit cells 20 on the front side via deep etched conduits (not shown) through the CMOS layer. Separate linking printhead ICs 12 are bonded to the support member 14 so that there are no printed artifacts across the join between neighbouring printhead IC's. Each IC 12 contains ten rows 26 of nozzles 32 . As shown in FIG. 4 , there are two adjacent rows 26 for each color to allow up to five separate types of ink. Each pair of rows 26 shares a common ink supply channel in the back side of the wafer substrate. There are 640 nozzles per row and 2×640=1280 nozzles per color channel, which equates to 5×1280=6400 nozzles per IC 12 . An A4/Letter width printhead requires a series of eleven printhead IC's (see for example FIG. 1 ), making the total nozzle count for the assembled printhead 11×6400=70 400 nozzles. Color and Nozzle Arrangement At 1600 dpi, the distance between printed dots needs to be 15.875 □m. This is referred to as the dot pitch (DP). The unit cell 20 has a rectangular footprint that is 2DP wide by 5DP long. To achieve 1600 dpi per color, the rows 26 are offset from each other relative to the feed direction 18 of the paper 48 as best shown in FIG. 4 . FIG. 5A shows the parallelogram that the nozzle forms by offsetting each subsequent row 26 by 5 DP. Linking Nozzle Arrangement The parallelogram 50 does not allow the array 22 to link with those of adjacent printhead IC's. To maintain a constant dot pitch between the edge nozzles of one printhead IC and the opposing edge nozzles of the adjacent IC, the parallelogram 50 needs to be slightly distorted. FIG. 5B shows the distortion used by the Udon design. A portion 30 of the array 22 is displaced or ‘dropped’ relative to the rest of the array with respect to the paper feed direction 18 . For convenience, the Applicant refers to this portion as the drop triangle 30 . The unit cells 20 on the outer edge of the drop triangle 30 are directly adjacent the unit cells 20 at the edge of the adjacent printhead IC 11 in terms of their dot pitch. In this way, the separate nozzle arrays link together as if they were a single continuous array. The ‘drop’ of the drop triangle 30 is 10 DP. Dots printed by the nozzles in the triangle 30 are delayed by ten ‘line times’ (the line time is the time taken to print one line from the printhead IC, that is fire all ten rows in accordance with the print data at that point in the print job) to match the triangle offset. There is a transition zone 28 between the drop triangle 30 and the rest of the array 22 . In this zone the rows 26 ‘droop’ towards the drop triangle 30 . Nine pairs of unit cells 20 sequentially drop by one line time (1 DP, 1 row time) at a time to gradually bridge the gap between dropped and normal nozzles. The droop zone is purely for linking and not necessary from a printing point of view. As shown in FIG. 6A , the rows 26 could simply terminate 10 DP above the corresponding row in the drop triangle 30 . However, this creates a sharp corner in the ink supply channels 50 in the back of the IC 12 (see FIG. 6B ). The sharp change of direction in the ink flow is problematic because outgassing bubbles can become lodged and difficult to remove from stagnation areas 54 at the corners 52 . FIG. 5C shows the configuration of the ink supply channels 50 in the back of an Udon printhead IC 12 . It can be seen that the droop zone 28 keeps the ink supply channels 50 less angled and therefore free of flow stagnation areas. Compatibility with Different Print Engine Controllers The Udon printhead IC, can operate in different modes depending on the print engine controller (PEC) from which it is receiving its print data. Specifically, Udon runs in two distinct modes—SoPEC mode and MoPEC mode. SoPEC is the PEC that the Applicant uses in its SOHO (small office, home office) printers, and MoPEC is the PEC used in its mobile telecommunications (e.g. cell phone or PDA) printers. Udon does not use any type of adaptor or intermediate interface to connect to differing PEC's. Instead, Udon determines the correct operating mode (SoPEC or MoPEC) when it powers up. In each mode, the contacts on each of the printhead IC's assume different functions. SoPEC Mode Connection FIG. 7 is a schematic representation of the connection of the Udon IC's 12 to a SoPEC 56 . Each of the printhead IC's 12 has a clock input 60 , a data input 58 , a reset pin 62 and a data out pin 64 . The clock and data inputs are each 2 LVDS (low voltage differential signalling) receivers with no termination. The reset pin 62 is a 3.3V Schmitt trigger that puts all control registers into a known state and disables printing. Nozzle firing is disabled combinatorially and three consecutive clocked samples are required to reset the registers. The data output pin 64 is a general purpose output but is usually used to read register values back from the printhead IC 12 to the SoPEC 56 . The interface between SoPEC 56 and the printhead 10 has six connections. MoPEC Mode Connection FIG. 8 shows the connection between a MoPEC 66 and the printhead IC's 12 of a printhead 10 installed in a mobile device. Some of the same connection pins are used when the IC operates in the MoPEC mode. However, as the MoPEC printheads 10 will be physically smaller (only three chips wide for printing onto business card sized media) and more frequently replaced by the user, it is necessary to simplify the interface between the MoPEC and the printhead as much as possible. This reduces the scope for incorrect installation and enhances the intuitive usability of the mobile device. The address carry in (ACI) 70 is the positive pin of the LVDS pair of clock input 60 in the SoPEC mode. The first printhead IC 12 in the series has the ACI 70 set to ground 68 for addressing purposes described further below. The negative pin 60 is grounded to hold it to ‘0’ voltage. The data out pin 64 connects directly to the ACI 70 of the adjacent printhead IC 12 . All the IC's 12 are daisy-chained together in this manner with the last printhead IC 12 in the series having the data out 64 connected back to the MoPEC 66 . In MoPEC mode, the reset pin 62 remains unconnected and the negative pin 72 of the data LVDS pair is grounded. The data and clock are inputted through a single connection using the self-clocking data signal discussed below. The daisy-chained connection of the IC's 12 and the self clocking data input 58 reduce the number of connections between MoPEC and the printhead to just two. This simplifies the printhead cartridge replacement process for the user and reduces the chance of incorrect installation. Combined Clock and Data The combined clock and data 58 is a pulse width modulated signal as shown in FIG. 9 . The signal 74 shows one clock period and a ‘0’ bit and the signal 76 shows one clock period and a ‘1’ bit. The Udon IC's 12 (when in MoPEC mode) takes its clock from every rising edge 78 as the signal switches from low to high (0 to 1). Accordingly, the signal has a rising edge 78 at every period. A ‘0’ bit drops the signal back to ‘0’ at ⅓ of the clock period. A ‘1’ bit drops the signal to ‘0’ at ⅔ of the clock period. The IC looks to the state of the signal at the mid point 80 of the period to read the ‘0’ or the ‘1’ bit. External Printhead IC Addressing Each of the printhead IC's 12 are given a write address when connected to the MoPEC 66 . To do this using a two wire connection between the PEC and the printhead requires an iterative process of broadcast addressing to each device individually. Udon achieves this by daisy-chaining the data output or one IC to the address carry in of the next IC. The default or reset value at the data output 64 is high or ‘1’. Therefore every printhead IC 12 has a ‘1’ address except the first printhead IC 12 which has its address pulled to ‘0’ by its connection to ground 68 . To give the IC's 12 unique write addresses, the MoPEC 66 sends a broadcast command to all devices with a ‘0’ address. In response to the broadcast command, the only IC with a ‘0’ address, re-writes its write address to a unique address specified by MoPEC and sets its data out 64 to ‘0’. That in turn pulls the ACI 70 of the second IC 12 in the series to ‘0’ so that when MoPEC again sends a broadcast command to write address ‘0’ so that the second IC, and only the second IC, rewrites its address to a new and unique address, as well as setting its data output to ‘0’. The process repeats until all the printhead IC's 12 have mutually unique write addresses and the last IC sends a ‘0’ back to MoPEC 66 . Using this system for addressing the IC's at start up, the interface need only have a connection for a combined data and clock ‘multi-dropped’ (connected in parallel) to all devices and a data out from the IC's back to MoPEC. As discussed above, a simplified electrical interface between the PEC and printhead cartridge enhances the ease and convenience of cartridge replacement. Power on Reset Udon printhead IC's 12 have a power on reset (POR) circuit. The ability to self initialize to a known state allows the printhead IC to operate in the MoPEC mode with only two contacts at the PEC/printhead 10 interface. The POR circuit is implemented as a bidirectional reset pin 62 (see FIG. 7 ). The POR circuit always drives out the reset pin 62 , and the IC listens to the reset pin input side. This allows SoPEC 56 to overdrive reset when required. PEC Interface Type Detection On power up, the Udon printhead IC 12 switches from mode to mode and suppresses fire commands until it determines the type of PEC to which it is connected. Once it selects the correct operating mode for the PEC, it will not try to align with another PEC type again until a software reset or power down/power up cycle. An Udon printhead IC 12 can be in three interface modes: SoPEC mode, where both clock and data 58 are LVDS (low voltage differential signalling) contacts pairs (see FIGS. 7 and 8 ); MoPEC single-ended mode, where clock and data are combined 58 and single ended (see FIG. 8 ) because the data is pulse width modulated along the clock signal; and, MoPEC LVDS mode, where the clock 60 is single ended and data 58 is LVDS (this mode can be used if there are EMI issues). Udon spends sufficient time in each state to align, then moves on in order if alignment is not achieved. Multi-Stage Print Data Loading In previous printhead IC designs, each unit cell had a shift register for the print data. Print data for the entire nozzle array was loaded and then, after the fire command from the PEC, the nozzles are fired in a predetermined sequence for that line of print. The shift register occupies valuable space in the unit cell which could be better used for a bigger, more powerful drive FET. A more powerful drive FET can provide the actuator (thermal or thermal bend actuator) with a drive pulse of sufficient energy (about 200 nJ) in a shorter time. A bigger more powerful FET has many benefits, particularly for thermally actuated printheads. Less power is converted to wasteful heat in the FET itself, and more power is delivered to the heater. Increasing the power delivered to the heater causes the heater surface to reach the ink nucleation temperature more quickly, allowing a shorter drive pulse. The reduced drive pulse allows less time for heat diffusion from the heater into regions surrounding the heater, so the total energy required to reach the nucleation temperature is reduced. A shorter drive pulse duration also provides more scope to sequence to the nozzle firings within a single row time (the time to fire a row of nozzles). Moving the print data shift registers out of the unit cells makes room for bigger drive FETs. However, it substantially increases the wafer area needed for the IC. The nozzle array would need an adjacent shift register array. The connections between each register and its corresponding nozzle would be relatively long contributing to greater resistive losses. This is also detrimental to efficiency. As an effective compromise, the Udon printhead IC stages the loading and firing of the print data from the nozzle array. Print data for a first portion of the nozzle array is loaded to registers outside the array of nozzles. The PEC sends a fire command after the registers are loaded. The registers send the data to the corresponding nozzles within the first portion where they fire in accordance to the fire sequence (discussed below). While the nozzles in the first portion fire, the registers are loaded with the print data for the next portion of the array. This system removes the register from the unit cell to make way for a larger, more powerful drive FET. However, as there are only enough registers for the nozzles in a portion of the array, the resistive losses in the connection between register and nozzle is not excessive. The drive logic on the IC 12 sends the print data to the array row by row. The nozzle array has rows of 640 nozzles in 10 rows. Adjacent to the array, 640 registers store the data for one row. The data is sent to the registers from the PEC in a predetermined row firing sequence. Previously, when the data for the entire array was loaded at once, the PEC could simply send the data for each row sequentially—row 0 to row 9 . However, with each row fired as soon as its data is loaded, the PEC needs to align with Udon's row firing sequence. Udon's normal operating steps are described as follows: 1. Program registers to control the firing sequence and parameters. 2. Load data into the registers for a single row of the printhead. 3. Send a fire command, which latches the loaded data in the corresponding nozzles, and begins a fire sequence. 4. Load data for the next row while the fire sequence is in progress. 5. Repeat for all rows in the line. 6. Repeat for all lines on the page. Temperature Controlled Profile Generator (TCPG) Regions Ink viscosity is dependent on the ink temperature. Changes in the viscosity can alter the drop ejection characteristics of a nozzle. Along the length of a pagewidth printhead, the temperature may vary significantly. These variations in temperature and therefore drop ejection characteristics leave artefacts in the print. To compensate for temperature variations, each Udon printhead IC has a series of temperature sensors which output to the on-chip drive logic. This allows the drive pulse to be conditioned in accordance with the current ink temperature at that point along the printhead and thereby eliminate large differences in drop ejection characteristics. Referring to FIG. 10 , each Udon IC 12 has eight temperature sensors 74 positioned along the array 22 . Each sensor 74 senses the temperature in the adjacent region of nozzles, referred to as Temperature Controlled Profile Generator regions, or TCPG regions 76 . A TCPG region 76 is a ‘vertical’ band down the IC 12 that shares temperature and firing data (see the row firing sequence described later). Pulse width is set for each color on the basis of region, and temperature within that region. Periodic Sensor Activation The sensors 74 allow temperature detection between 0° C. and 70° C. with a typical accuracy after calibration of 2° C. Individual temperature sensors may be switched off and a region may use the temperature sensor 74 of an adjoining region 78 . This will save power with minimal effect on the correct conditioning of the drive pulse as the sensors will sense heat generated in regions outside their own because of conduction. If the steady state operating temperatures shown little or no variation along the IC, then it may be appropriate to turn off all the sensors except one, or indeed turn off all the sensors and not use any temperature compensation. Reducing the number of sensors operating at once not only reduces power consumption, but reduces the noise in other circuits in the IC. Temperature Categories Each TCPG region 76 has separate registers for each of the five inks. The temperature of the ink is categorised into four temperature ranges defined by three predetermined temperature thresholds. These thresholds are provided by the PEC. The profile generator within the Udon logic adjust the profile of the drive pulse to suit the current temperature category. Sub-Ejection Pulses Heat dissipates into the ink as the heater temperature rises to the bubble nucleation temperature. Because of this, the temperature of the ink in a nozzle will depend on how frequently it is being fired at that stage of the print job. A pagewidth printhead has a large array of nozzles and at any given time during the print job, a portion of the nozzles will not be ejecting ink. Heat dissipates into regions of the chip surrounding nozzles that are firing, increasing the temperature of those regions relative to that of non-firing regions. As a result, the ink in non-ejecting nozzles will be cooler than that in nozzles firing a series of drops. The Udon IC 12 can send non-firing nozzles ‘sub-ejection’ pulses during periods of inactivity to keep the ink temperature the same as that of the nozzles that are being fired frequently. A sub-ejection pulse is not enough to eject a drop of ink, but heat dissipates into ink. The amount of heat is approximately the same as the heat that conducts into the ink prior to bubble nucleation in the firing nozzles. As a result, the temperature in all the nozzles is kept relatively uniform. This helps to keep viscosity and drop ejection characteristics constant. The sub-ejection pulse reduces its energy by shortening its duration. Drive Pulse Profiling Actively changing the profile of the drive pulse offers many benefits including: optimum firing pulse for varying inks and temperatures warming a region before it fires shutting down or just slowing down an IC that gets too hot (Udon provides the information, PEC controls speed) adjusting for voltage drop caused by distance (extra resistance) from the power source reducing the energy input to the chip, as warm ink requires less energy to eject than cold ink The pulse profile can vary according to temperature and ink type. The firing pulses generated by the TCPG regions are stored in large registers that contain values for each of five inks in each of four temperature ranges, plus universal ink and region values, and threshold values. These values must be supplied to the Udon and may be stored in and/or delivered by the QA chip on the ink cartridge (see RRC001US incorporated herein by reference), the PEC, or elsewhere. Controlling the Pulse Width It is convenient to adjust the firing pulses by varying the pulse duration instead of voltage or current. The voltage is externally applied. Varying the current would involve resistive losses. In contrast, the pulse timing is completely programmable. Ideal ink ejection firing pulses for Udon are typically between 0.4 □s and 1.4 □s. Sub-ejection firing pulses are usually less than 0.3 □s. More generally, the firing pulse is a function of several factors: MEMs characteristics Ink characteristics Temperature FET type The magnitude of the optimum firing pulse may vary depending on color and temperature. Udon stores the ejection pulse time for each color, in all temperature zones, in all regions. Row Firing Sequence If all nozzles in a row were fired simultaneously, the sudden increase in the current drawn would be too high for the printhead IC and supporting circuitry. To avoid this, the nozzles, or groups of nozzles, can be fired in staggered intervals. However, firing adjacent nozzles simultaneously, or even consecutively, can lead to drop misdirection. Firstly the droplet stalks (the thin column of ink connecting an ejected ink drop to the ink in the nozzle immediately prior to droplet separation) can cause micro flooding on the surface of the nozzle plate. The micro floods can partially occlude an adjacent nozzle and draw an ejected drop away from its intended trajectory. Secondly, the aerodynamic turbulence created by one ejected drop can influence the trajectory of a drop ejected simultaneously (or immediately after) from a neighboring nozzle. The second fired drop can be drawn into the slipstream of the first and thereby misdirected. Thirdly the fluidic cross talk between neighboring nozzles can cause drop misdirection. Udon addresses this by dispersing the group of nozzles that fire simultaneously, and then fires nozzles from every subsequent dispersed group such that sequentially fired nozzles are spaced from each other. The nozzle firing sequence continues in this manner until all the nozzles (that are loaded with print data) in the row have fired. To do this, each row of nozzles is divided into a number of adjacent spans and one nozzle from each span fires simultaneously. The subsequently firing nozzle from each span is spaced from the previously firing nozzle by a shift value. The shift value can not be a factor of the span number (that is, the shift and the span should be mutually prime) so nozzles at the boundary between neighbouring spans do not fired simultaneously, or consecutively. Span The span is the number of consecutive nozzles in the row from which only one nozzle will fire at a time. FIG. 11 shows a partial row of nozzles being fired with a span of three, and the same row segment with a span of five. For the purposes of illustration, the shift value is one. However, as discussed above, this is not an appropriate shift value in practice as the adjacent nozzles will fire consecutively. The turbulent wake from the drop fired from the first nozzle can interfere with the drop fired from the adjacent model immediately afterwards. It can also be a problem for the ink supply flow to the adjacent nozzles. For a span of three, there are three firings before the entire row is fired. First firing: every third nozzle in a row fires. Second firing: the nozzle to one side of the first nozzle fires. Third firing: the nozzle two across from the first nozzle fires-all nozzles on this row have now fired. The nozzles in row N+2 now begin their fire cycle using the same span pattern. One third of a row's nozzles fire at any one time. For a span of five, there are five firings before the entire row is fired and one fifth of the row's nozzles fire at any one time. At the extremes (for Udon printhead IC's): span=1 fires all nozzles in a row simultaneously, draws too much current and will damage the IC; span=640 fires one nozzle at a time, but may take too long to complete in the time allotted to a single row. In any case, span only controls the maximum number of nozzles that are able to fire at any one time. Each individual nozzle still needs a 1 in its shift register to actually fire. In the examples below, we assume that the IC is printing a solid color line, so every nozzle of the color will fire. In reality, this is rarely the case. Shift The examples shown in FIG. 11 have a shift value of one. That is, one nozzle fires, then the next nozzle left fires, then the next, etc. As discussed above, this is impractical. FIG. 12 shows a segment of the nozzle row with a span of 5 with a span shift of 3. First firing: column 1 fires. Second firing: the firing nozzle is 3 nozzles across at column 4 . Third firing: the count has wrapped around and is back at nozzle 2 . Fourth firing: nozzle 5 fires. Fifth firing: nozzle 3 fires—all 5 nozzles in the span have now fired. To fire every nozzle in the row exactly once, the shift can not be a factor of the span, i.e. the span can not be divided by the shift (without remainder). To maximize droplet separation in time and space and still fire every nozzle exactly once per row, the closest mutual prime to the square root of the span should be chosen for span shift. For example, for a span of 27, a span shift of 5 would be appropriate. Firing Delay Firing all the nozzles in a row simultaneously, will draw a large amount of current that remains (approximately) constant for the duration of the row time. This still requires the power supply to step from zero current to a maximum current in a very short time. This creates a high rate of change of current drawn until the maximum value is reached. Unfortunately, a rapid increase in the current creates inductance which increases the circuit impedance. With high impedance, the drive voltage ‘sags’ until the inductance returns to normal, i.e. the current stops increasing. In printhead IC's, it is necessary to keep the actuator supply voltage within a narrow range to maintain consistent ink drop size and directionality. As the firing pulses in each region can be varied by the TCPG, it can be used to delay the start of firing in each region across the printhead. This reduces the rate of change in current during firing. FIGS. 13A and 13B show the relationship between region firing delay and current drain. FIG. 13A shows the two extremes of power usage when printing a solid line of a color (this is the worst case for power supply because 80 dots will fire across the region). FIG. 13A shows no firing delay between regions. Each region has 4 spans of 20 nozzles each. Each of the regions fire for the entire row time (row time is the time available for a complete row of nozzles to fire). Therefore, at any time during the row time, four nozzles from all of the eight regions are firing (drawing current). Hence the profile of the supply current is a long flat step function 78 and identical for each region. The profile for the entire row is the accumulated step function 80 of the individual profiles 78 . Theoretically the leading edge 90 of step function 80 is vertical but in fact it is very steep until it reaches the maximum current level 82 . The high rate of change in the current can cause the undesirable voltage sags. FIG. 13B shows the current supply profiles when the regions are fired in stages. To stagger the firing of each region, the time in which the nozzles in each span can fire must be reduced. In the example shown in FIG. 13B , each span has half the row time in which to fire its nozzles. To compress the time needed for each span to fire, the number of nozzles in the span can be reduced. For example, the span in FIG. 13B is 10, so 8 nozzles (10×8=80 nozzles/region) from each span will fire simultaneously. The cumulative current drawn for eight nozzles is greater than that for the four nozzles firing per span shown in FIG. 13A . So the current drawn for each region in FIG. 13B is twice that of the regions in FIG. 13A , but the current is drawn for half the time. Region 1 is supply with current 84 at the beginning of the row time. The current supply 94 to region 2 starts after a set delay period and region 3 is similarly delayed relative to region 2 , and so on until region 8 starts its firing sequence. The delays for each region need to be timed so that region 8 starts firing at or before half the row time has elapsed. The cumulative current supply profile 86 shows the series of 8 rapid steps in the current supply as it reaches its maximum value 88 . The maximum current 88 is greater than the maximum current 82 in the non-delayed region firing, but the rate of increase in the supply current 92 is less. This induces less impedance in the circuit so that the voltage sag is lower. In each case, the total energy used is the same for a given row time but the distribution of energy consumption is adjusted. Normal Firing Order As discussed above, print data is sent to the printhead IC's 12 one row at a time followed by a fire command. Previously, each individual unit cell in the nozzle array had a shift register to store the print data (a ‘1’ or ‘0’) for each nozzle, for each line time (the line time is the time taken for the printhead to print one line of print). The print data for the entire array would be loaded into the shift registers before a fire command initiated the firing sequence. By loading and firing the print data for each line in stages, a smaller number of shift registers can be positioned adjacent the array instead of within each unit cell. Removing the shift registers from the unit cell 20 allows the drive FET 40 (see FIG. 2 ) to be larger. This improves the printhead efficiency for the reasons set out below. Thermal printhead IC's are more efficient if the vapor bubble generated by heater element is nucleated quickly. Less heat dissipates into the ink prior to bubble nucleation. Faster nucleation of the bubble reduces the time that heat can diffuse into wafer regions surrounding the heater. To get the bubble to nucleate more quickly, the electrical pulse needs to have a shorter duration while still providing the same energy to the heater (about 200 nJ). This requires the drive FET for each nozzle to increase the power of the drive pulse. However, increasing the power of the drive FET increases its size. This enlarges the wafer area occupied by the nozzle and its associated circuitry and therefore reduces the nozzle density of the printhead. Reducing the nozzle density is detrimental to print quality and compact printhead design. By removing the shift register from the unit cell, the drive FET can be more powerful without compromising nozzle density. The Udon design writes data to the nozzle array one row at a time. However, a printhead IC that loaded and fired several rows at a time would also be achieving the similar benefits. However, it should be noted that the electrical connection between the shift register and the corresponding nozzle should be kept relatively short so as not to cause high resistive losses. Loading and firing the print data one row at a time requires the PEC to send the data in the row order that it is printed. Previously the data for the entire nozzle array was loaded before firing so the PEC was indifferent to the row firing order chosen by the printhead IC. With Udon, the PEC will need to transmit row data in a predetermined order. Printhead nozzles are normally fired according to the span/shift fire sequence and the delayed region start discussed above. The supply channels 50 in the back of the printhead IC 12 (see FIG. 5C ) supply ink to two adjacent rows of nozzle on the front of the IC, that is rows 0 and 1 eject the same color, rows 2 and 3 eject another color, and so on. The Udon printhead IC has ten row of nozzles, these can be designated colors CMYK,IR (infra-red ink for encoding the media with data invisible to the eye) or CMYKK. To avoid ink supply flow problems, every second row is fired in two passes, that is row 0 , row 2 , row 4 , row 6 , row 8 , then row 1 , row 3 , row 5 , and so on until all ten row are fired. Row firings should be timed such that each row takes just under 10% of the total line time to fire. A fire command simply fires the data that is currently loaded. When operating in SoPEC mode, Udon printhead IC receives a ‘data next’ command that loads the next row of data in the predetermined order. In MoPEC mode, each row of data must be specifically addressed to its row. Taking paper movement into account, a row time of just less than 0.1 line time, together with the 10.1DP (dot pitch) vertical color pitch appears on paper as a 10DP line separation. Odd and even same-color rows of nozzles, spaced 3.5DP apart vertically and fired 0.5 line time apart results as dots on paper 5DP apart vertically. Fire Cycle FIG. 14 shows the data flows and fire command sequences for a line of data. When a fire command is received in the data stream, the data in the row of shift registers transfers to a dot-latch in each of the unit cells, and a fire cycle is started to eject ink from every nozzle that has a 1 in its dot-latch. Meanwhile the data for the next row in the firing order is loaded. Drop Triangle and Droop Section Firing Delay Drop compensation is the compensation applied by Udon drive logic 46 (see FIG. 2 ) to the sloping region 28 and drop triangle 30 of nozzles at the left of the nozzle array 22 on each IC 12 (see FIG. 5C ). As shown in FIG. 15 , the print data to the nozzles that are displaced from the rest of the array 22 needs to be delayed by a certain number of line times. FIG. 15 shows the nozzles in one row 26 of the IC 12 . The nozzles in the drop triangle 30 are all displaced 10 dot pitches from the non-displaced nozzles in the row. The nozzles in the droop section 28 that connects the drop triangle 30 and the non-displaced nozzles have a displacement that indexes by one dot pitch every two nozzles. In the sloping droop region 28 the drive logic indexes the delay in firing the dot data correspondingly. Nozzle Blockage Clearing During periods of inactivity, or even between pages, and especially at higher ambient temperatures, nozzles may become blocked with more viscous or dried ink. Water can evaporate from the ink in the nozzles thereby increasing the viscosity of the ink to the point where the bubble is unable to eject the drop. The nozzle becomes clogged and inoperable. Many printers have a printhead maintenance regime that can recover clogged nozzles and clean the exterior face of the printhead. These create a vacuum to suck the ink through the nozzle so that the less viscous ink refills the nozzle. A relatively large volume of ink is wasted by this process requiring the cartridges to be replaced more frequently. Udon printhead IC's have a maintenance mode that can operate before or during a print job. During maintenance mode the drive logic generates a de-clog pulse for the actuators in each nozzle unless the dead nozzle map (described below) indicates that the actuator has failed. To operate during a print job, the nozzles should fire the de-clog pulse into the gap between pages without interruption to the paper. The de-clog pulse is longer than the normal drive pulses. The bubble formed from a longer duration pulse is larger and imparts a greater impulse to the ink than a firing impulse. This gives the pulse the additional force that may be needed to eject high viscosity ink. As a preliminary measure, the de-clog pulse can be preceded by a series of sub-ejection pulses to warm the ink and lower viscosity. FIG. 16 shows a typical de-clog pulse train with a series of short (relative to a firing pulse) sub-ejection pulses 94 followed by a single de-clog pulse 96 . The individual sub-ejection pulses 94 have insufficient energy to nucleate a bubble and therefore eject ink. However, a rapid series of them raises the ink temperature to assist the subsequent de-clog pulse 96 . Open Actuator Testing The Udon printhead IC 12 supports an open actuator test. The open actuator test (OAT) is used to discover whether any actuators in the nozzles array have burnt out and fractured (usually referred to as becoming ‘open’ or ‘open circuit’). Fabrication of the MEMS nozzle structures on wafer substrates will invariably result in some defective nozzles. These ‘dead nozzles’ can be located using a wafer probe immediately after fabrication. Knowing the location of the dead nozzles, the print engine controller (PEC) can be programmed with a dead nozzle map. This is used to compensate for the dead nozzles with techniques such as nozzle redundancy (the printhead IC is has more nozzles than necessary and uses the ‘spare’ nozzles to print the dots normally assigned to the dead nozzles). Unfortunately, nozzles also fail during the operational life of the printhead. It is not possible to locate these nozzles using a wafer probe once they have been mounted to the printhead assembly and installed in the printer. Over time, the number of dead nozzles increases and as the PEC is not aware of them, there is no attempt to compensate for them. This eventually causes visible artifacts that are detrimental to the print quality. In thermal inkjet printheads and thermal bend inkjet printheads, the vast majority of failures are the result of the resistive heater burning out or going open circuit. Nozzles may fail to eject ink because of clogging but this is not a ‘dead nozzle’ and may be recovered through the printer maintenance regime. By determining which nozzles are dead with an on-chip test, the print engine controller can periodically update its dead nozzle map. With an accurate dead nozzles map, the PEC can use compensation techniques (e.g. nozzle redundancy) to extend the operational life of the printhead. The Udon IC open actuator test compares the resistance of the actuator to a predetermined threshold. A high (or infinite) resistance indicates that the actuator has failed and this information is fed back to the PEC to update its dead nozzle compensation tables. It is important to note that the OAT can discover open circuit nozzles, but not clogged nozzles. Thermal actuators and thermal bend actuator both use heater elements and the OAT can be equally applied to either. Likewise, the drive FET can be N-type or P-type. FIGS. 17A and 17B show the circuits for the OAT as applied to a single unit cell with a single heater element driven by a p-FET and an n-FET respectively. In FIG. 17A , the drive p-FET 40 is enabled during printing whenever the ‘row enable’ (RE) 98 and ‘column enable’ (CE) 100 are both asserted (receive ‘1’s at their contacts). Enabling the drive FET 40 opens the heater element 34 to Vpos 104 to activate the unit cell. When the row enable 98 or the column enable 100 are not asserted, the bleed n-FET is enabled. The bleed n-FET 112 ensures that the voltage at the sense node 120 is pulled low when the unit cell is not activated to eliminate any electrolysis path. When the OAT 106 is asserted, the AND gate 108 pulls the gate of the drive p-FET 40 high to disable it. Asserting the OAT 106 also pulls the gate of the sense n-FET 114 high to connect the sense output 116 to the sense node 120 . With the bleed n-FET 112 disabled the voltage at the sense node 120 will still be pulled low through the heater element 34 to ground 68 . Accordingly, the sense output 116 is low to indicate that the actuator is still operational. However, if the heater element 34 is open (failed), the voltage at the sense node 120 remains high and this pulls the sense output 116 high to indicate a dead nozzle. This is fed back to the PEC which updates the dead nozzle map and initiates measures to compensate (if possible). The unit cell circuitry shown in FIG. 17B uses a drive n-FET 40 . In this embodiment, asserting the row enable 98 and the column enable 100 pulls the gate of the drive n-FET 40 high to enable it and allow Vpos 104 to drain to ground through the heater 34 . Again the bleed p-FET 118 is disabled whenever the row enable 98 and column enable 100 are asserted. To initiate an actuator test, the OAT 106 is asserted, together with the row enable 98 and column enable 100 . This disables the drive n-FET 40 by pulling the gate low using NAND logic 110 . It also opens the sense n-FET 114 to connect the sense output 116 to the sense node 120 . With the heater 34 insulated from ground 68 when the drive FET 40 is disabled, the sense node 120 is pulled high and a high sense output 116 indicates a working actuator. If the heater 34 is broken, the sense node 120 is left at low voltage following the last time the drive FET 40 was enabled. Accordingly when the OAT is enabled, the sense output 116 is low and the PEC records the dead nozzle to the dead nozzle map. It will be appreciated that the open actuator test should be performed shortly after the printhead IC has been printing. After a period of inactivity, the bleed p-FET 118 or n-FET 112 drops the sense node to low voltage. The gap in printing between pages is a convenient opportunity to perform an open actuator test. The present invention has been described herein by way of example only. Skilled workers in this field will readily recognise many variations and modification which do not depart from the spirit and scope of the broad inventive concept.
Provided is test circuitry for testing a thermal actuator of a printhead nozzle arrangement of a printhead. The circuitry includes an open actuator test input, a column enable input and a row enable input. A drive transistor operatively links said thermal actuator to a power supply, and a bleed transistor is arranged in parallel with the thermal actuator. The circuitry also includes a sense transistor operatively linking an output of the drive transistor and inputs of the thermal actuator and bleed transistor to a sensing node, as well as a controller configured to deactivate the bleed and sense transistors and to activate the drive transistor when the column enable and row enable inputs are activated to link the thermal actuator to the power supply, and to activate the bleed and sense transistors when the open actuator test input is activated, so that the thermal actuator is short-circuited and the sense node is pulled high if the thermal actuator is open-circuit.
1
CROSS-REFERENCE TO RELATED APPLICATIONS The present application claims priority to German patent application number 10243778.5 filed on 20 Sep. 2002, which is herein incorporated by reference. BACKGROUND OF THE INVENTION The present invention relates to an actuating device with an electromotive rotary drive and more particularly to the actuating element, which can be driven rotatably about an axis of rotation between a first end position and a second end position and further acted upon out of the first end position by a spring. In actuating devices of this type, it is known to operate the actuating element by means of the electromotive rotary drive counter to the force of the spring and over the entire actuating travel between the first and second end positions. During operation of the actuating device, a permanent operation of the electromotive actuating drive is also required. A permanent supply of current and therefore a permanent expenditure of energy is also consequently necessary. Since, in this case, the activating electronics of the actuating drive is also operated permanently, the load on these electronics, particularly as a result of heating, is high and necessitates higher-grade electrical and electronic components, with the result that the activation electronics are costly. If the actuating device serves for regulating the operation of a further device, such as, for example, for regulating the stream of a cooling liquid in a coolant circuit of the internal combustion engine for a motor vehicle, it is necessary that, in the event of a failure of the actuating device, a sufficient cooling liquid stream continues to be maintained, so that the internal combustion engine can be operated further, at least in an emergency running mode. This is not possible with known actuating devices, since, in the event of failure, the actuating element is moved into the second end position by the spring. This means that the cooling circuit is either completely shut off or completely open, the both of which do not correspond to the cooling requirements. BRIEF SUMMARY OF THE INVENTION An object of the present invention is to provide an actuating device of the type initially mentioned above, which, in the event of a failure of its electromotive rotary drive, ensures that an intermediate position of the actuating element is assumed. The instant drive would operate with a saving of energy and further have a simple and cost-effective construction. These and other objects are achieved by the present electromotive actuating drive. The present actuating device comprises a reversing drive. Spring action upon the actuating element is effective between the first end position and an intermediate position and is ineffective between the intermediate position and the second end position. The intermediate position lies between a first and a second end position. Since the actuating element is adjusted and held counter to the force of the spring between the first end position and the middle position only, an increased expenditure of energy is necessary only in this actuating range. In the actuating range between the middle position and the second end position, the motive drive is necessary only in order to adjust the actuating element, without overcoming a spring force, but not in order to hold the actuating element in position. When the selected position is reached, the actuating drive is switched off, so that only low energy has to be expended for adjustment. No energy at all has to be expended for holding the element in an assumed position. Since the spring acts only in a partial range of the total range of adjustment between the first and second end position, it can be designed with lower force, as a result of which only a smaller amount of energy is required for the electromotive rotary drive. Thus, not only is the necessary energy requirement low, but also simpler and more cost-effective electrical and electronic components for activation and a motive rotary drive designed to be smaller may be used, since these parts are subjected to a lower thermal load. At the same time, however, it is ensured that, in the event of a failure of the electromotive rotary drive, the actuating element is set automatically into an emergency running position. In a simple and cost-effective design, the electromotive rotary drive may be a direct-current drive. The actuating element may be arranged on a rotatably mounted shaft that can be rotatably driven by the electromotive actuating drive. For the simple transmission of the rotary drive, the shaft has arranged on it, fixedly in terms of rotation, a gearwheel or toothed quadrant which can be rotatably driven by a drive pinion of the electromotive rotary drive directly or via one or more intermediate wheels. A simply construction is achieved in that the first end position is determined by a first limit stop and/or the second end position is determined by a second limit stop. Accordingly, by means of the stops, the rotational movement of the gearwheel or toothed quadrant or of the actuating element or of a component connected to the gearwheel, toothed quadrant or actuating element, can be limited. In this case, the ends of the toothed quadrant which are directed in the circumferential direction can be capable of butting up against the first and/or the second limit stop. Only a few simple components are necessary for spring action upon the actuating element, between the first end position and the intermediate position, when a stop element mounted freely rotatably about the axis of rotation is acted upon by the spring. The actuating element can be taken along in the direction of the first end position on the gearwheel or toothed quadrant counter to the force of the spring. The rotatability of the stop element in the opposite direction is limited by an intermediate stop determining the intermediate position. In this case, to achieve a further savings in terms of components, the stop element may have a driver which can be acted upon by the gearwheel or toothed quadrant in the direction of the first end position, and the stop element may have an intermediate-position stop which, in the intermediate position, is capable of butting up against the intermediate stop in the direction of the second end position. If the stop element is a stop disk which is mounted freely rotatably on the shaft of the actuating element, only a small amount of installation space is necessary for this simply constructed component. Likewise, only a small amount of installation space is necessary when the spring is a spiral spring having one end fixed and another end affixed to the stop element. In this case, the spiral spring may act with its one end, in particular with its radially outer end, upon a spring driver of the stop element. If the spiral spring surrounds the shaft, a compact construction is achieved. There is a particular savings in terms of construction space when an actuating-device housing possesses a bowl-like recess. Into this recess one end of the shaft projects approximately coaxially. The spiral spring, the stop element, and the gearwheel or toothed quadrant may be arranged in a sandwich-like manner in the bowl-like recess. In addition, the actuating-device housing may possess a motor chamber for receiving the electromotive rotary drive. No separate components are required when the first limit stop and/or the second limit stop and/or the intermediate stop are arranged on the actuating-device housing. The actuating element may be a rotary slide of a rotary-slide valve. The valve passage may be closed by means of a rotary slide. The slide may be driven rotatably, counter to the force of the spring, out of the closing position and into a partially open position. The slide may further be driven, free of a counterforce, out of the partially open position and into a fully open position. In this example, the partially open position may correspond to the intermediate position. In the present example, in the event of failure of the electromotive rotary drive, when the slide is in the partially open or intermediate position, a sufficient flow of medium through the rotary-slide valve is maintained in order to ensure emergency operation of a flow dependent unit. By means of the rotary slide, one or more further valve passages can be opened and/or can be shut off. A simple construction is obtained when the rotary slide is mounted rotatably in a rotary-slide chamber of the actuating-device housing, and one or more flow inlets and/or flow outlets issuing into the rotary-slide chamber and being capable of being overlapped with one or more flow passages of the rotary slide. In this case, the flow inlets and/or flow outlets may issue into the rotary-slide chamber approximately radially and/or-approximately axially. If the rotary-slide valve is a regulating valve in a coolant circuit of an internal combustion engine, then, in the event of a failure of the electromotive rotary drive, cooling of the internal combustion engine so as to ensure at least emergency operation is maintained. The maintenance is effectively simply. The coolant circuit, as is known in the art, may carry a cooling medium such as engine coolant liquid. The present invention further comprises An actuating device, comprising: an electromotive rotary drive for driving an actuating element about an axis of rotation between a first and a second end position, a spring for acting upon said actuating element in said first end position, wherein said electromotive actuating drive is a reversing drive and said spring action upon said actuating element is effective between said first end position and an intermediate position and is further ineffective between said intermediate position and said second end position, the intermediate position lying between said first and second end position. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS The novel features believed characteristic of the invention are set out in the claims below. The invention itself, however, as well as other features and advantages thereof, are best understood by reference to the detailed description, which follows, when read in conjunction with the accompanying drawing, wherein: FIG. 1 depicts a perspective view of an actuating device of a rotary-slide valve; FIG. 2 depicts a perspective exploded illustration of the actuating device according to FIG. 1 ; and FIG. 3 depicts an illustration of the rotary-slide positions over the regulating range of the actuating device according to FIG. 1 . DETAILED DESCRIPTION OF THE INVENTION The present invention will be described with respect to a rotary slide valve as being a regulating valve for an internal combustion engine coolant system. The present actuating device drives the rotary slide. For clarity purposes, details about the coolant system and internal combustion engine are not depicted. It is within the scope of the present invention that it find application beyond that discussed below. As depicted in FIG. 3 , the present regulating valve comprises a rotary slide 3 rotatably mounted in a rotary-slide chamber 1 of an actuating-device housing 2 . The regulating valve includes two radial flow passages 4 and 5 . The rotary chamber includes a short-circuit outlet 6 and a cooling outlet 7 . The flow passages 4 and 5 are positioned on the rotary slide such that the slide 3 , in a first position 40 , shuts or seals off the rotary chamber to both outlets 6 and 7 , and in a second position 50 , the short-circuit outlet remains open, while the cooling outlet remains closed. In a still third position 60 , it is the short-circuit outlet which remains closed while the cooling outlet is open. As depicted in FIGS. 1 and 2 , the rotary slide chamber 1 comprises a bowl-like design. The chamber is axially connected with a flow inlet (not shown) via which coolant is supplied into the chamber. A corresponding orifice in the bottom of the chamber is included. A shaft 8 projects through the orifice. The shaft is fixedly connected to the rotary slide 3 . The shaft is also coaxially connected to the slide. A first end of the shaft projects through the chamber bottom and a second end projects into recess 9 . The recess 9 is also bowl-like. Actuating device housing 2 comprises recess 9 . The shaft 8 second end projecting from the recess is first surrounded by a spiral spring 10 . The radially inner end of the spring 10 is arranged fixedly in the region of the bottom 11 of the recess 9 . The radially outer end of spring 10 comprises a hook 12 . A stop disk 14 is included. The stop disk 14 includes a spring driver 13 which is engaged by hook 12 . The stop disk is freely and rotatably mounted on shaft 8 , parallel to spiral spring 10 . A toothed quadrant 15 is fixedly connected to shaft 8 such that rotational movement from the shaft is imparted on the quadrant. The quadrant is also sandwiched with and arranged atop of stop disk 14 . The stop disk 14 includes an axially directed driver 16 . The driver projects into the path of movement of the toothed quadrant 15 and via which the stop disk 14 , rotating until the toothed quadrant 15 comes to bear with one end 22 against a first limit stop 17 , comes into bearing contact and the spiral spring 10 being tensioned. The first limit stop 17 is arranged fixedly on the actuating-device housing 2 . The toothed quadrant 15 can be rotated in the opposite direction of rotation until it comes to bear against a second limit stop 18 . The stop disk 14 includes an intermediate-position stop 19 along its circumference. The stop disk 14 , along with toothed quadrant 15 freely rotate about shaft 8 , until stop 19 comes into contact with an intermediate stop 20 . In FIG. 2 , intermediate stop 20 is shown with second stop 18 . The intermediate stop may be positioned elsewhere between first and second stops 17 and 18 . When stop 19 comes into contact with stop 20 , the stop disk 14 and toothed quadrant 15 are prevented from rotating further in the direction of travel. However, since the intermediate-position stop 19 leads toothed quadrant end 21 in the direction facing second limit stop 18 , the toothed quadrant 15 can still rotate further without the stop disk 14 , before this rotational movement is limited by abutment against the second limit stop 18 . An intermediate pinion 23 engages toothed quadrant 15 . The pinion is connected, fixed and coaxially, to intermediate wheel 24 . Wheel 24 , in turn is connected with drive pinion 25 of a reversibly drivable direct-current (DC) motor 26 . The DC motor 26 is arranged in a motor chamber of the actuating-device housing 2 . The aforementioned connections generally refer to toothed connections between the mentioned components. Other such connections envisioned by one skilled in the art would be applicable. When the direct-current motor 26 is not operable or dead, the toothed quadrant 15 is moved by the spiral spring 10 , via the stop disk 14 , out of a position nearer to the first limit stop 17 and as far as into the intermediate position in which the intermediate-position stop 19 comes to bear against the intermediate stop 20 . In this intermediate position, the rotary slide 3 , co rotated via the shaft 8 , is then in a partial opening position, in which the cooling outlet 7 is partially opened, so that cooling liquid can flow to the internal combustion engine and cool the latter. If the cooling connection 7 is to be opened further and, if appropriate, completely, current is supplied to the direct-current motor 26 until the rotary slide 3 has reached the desired opening position. With the supply of current being terminated, the rotary slide 3 remains in this position. Due to the drive reversibility, the rotary slide 3 can be moved in both directions of rotation. If the cooling outlet 7 is to be opened to a lesser extent than the partial opening position, current is supplied to the direct-current motor 26 in such a way that the toothed quadrant 15 moves with its end 22 in the direction of the first limit stop 17 . Since, in this case, the stop disk 14 is taken along by the toothed quadrant 15 via the driver 16 , the spiral spring 10 is also tensioned, so that its force also has to be overcome (see for example FIG. 1 ). This movement leads first to a further closing of the cooling outlet 7 up to the complete shut-off of the latter and to an opening of the short-circuit outlet ( 50 ). When the toothed quadrant 15 is rotated further toward the first limit stop 17 , a shut-off of the short-circuit outlet 6 also takes place ( 40 ). FIG. 3 depicts the various intermediate positions of the regulating valve over the entire range of adjustment 27 of the rotary slide 3 . In this case, the illustration on the left ( 40 ) shows the fully closed position of both outlets 6 and 7 , in which the direct-current motor 26 , overcoming the force of the spiral spring 10 , has moved the toothed quadrant 15 until it comes to bear against the first limit stop 17 . When the toothed quadrant 15 is driven out of this position and in the direction of the second limit stop 18 , a rotation of the rotary slide 3 takes place. The slide rotation is effected with the cooperation of the spiral spring 10 over a range 28 , short circuit operating range, and into the intermediate position. In the intermediate position, in which the short-circuit outlet 6 is then closed and the coolant outlet 7 is partially opened, the effective range of the spiral spring 28 ends. From then on, an adjustment of the rotary slide 3 into its fully open position, in which the toothed quadrant 15 comes to bear against the second limit stop 18 , may occur without a spring force having to be overcome. The invention being thus described, it will be obvious that the same may be varied in many ways. The variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
The present invention relates to an actuating device with an electromotive rotary drive, via which an actuating element can be driven rotatably about an axis of rotation between a first end position and a second end position and can be acted upon out of the first end position by a spring. The electromotive actuating drive includes a reversing drive and the spring action upon the actuating element is effective between the first end position and an intermediate position. The spring action is ineffective between the intermediate position and the second end position. The intermediate position lies between the first end position and the second end position.
7
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to paper-making machines, and, more particularly, to paper-making machines with an air press system. 2. Description of the Related Art Press systems have long been relied upon to aid in the dewatering and in the forming of paper. Mechanical systems employing a series of rolls, shoes, etc. are the most common. More recently, development of air press systems has begun. Semipermeable membranes have been used to convey paper webs since such membranes provide channels through which water may be conveyed away from a paper web. An example of such a membrane in the form of a laser drilled forming fabric is described in U.S. Pat. No. 5,837,102 (Graf), entitled “Perforated and Embossed Sheet Forming Fabric,” issued Nov. 17, 1998, which is assigned to the assignee of the present invention and herein incorporated by reference. SUMMARY OF THE INVENTION The present invention provides an apparatus for processing a continuous fiber web that provides a guide roll for controlling a lateral position of the membrane on a fiber web roll and provides a tension roll for controlling a degree of slack and thus, conversely, an amount of tension in the membrane. The invention comprises, in one form thereof, a device for processing a continuous fiber web that includes a membrane, a pressurized enclosure, a tension roll and a guide roll. The pressurized enclosure includes at least a first roll and defines an air press chamber. The air press chamber has a perimeter with the first roll partially defining that perimeter. Additionally, the first roll carries the membrane. The tension roll also carries the membrane and is movable toward and away from the first roll. The guide roll further carries the membrane and is positioned between the first roll and the tension roll. The guide roll has opposite ends, at least one of which is pivotable toward and away from the first roll. An advantage of the present invention is that a longer membrane may be accommodated, thus promoting longer belt life by reducing the time spent in the nips by any given section of the membrane. Another advantage is a centering mechanism is available that counteracts the tendency of the membrane to meander along the length of a fiber web roll. Yet another advantage is that contact with and eventual loosening of the end seals of an air press belt run may be avoided by keeping the membrane generally centered. A yet further advantage is that a seal at each nip between mating rolls is better maintained by using crown compensating rolls as the rolls. 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 schematic view of a first embodiment of an air press system of the present invention; FIG. 2 is a schematic view of the membrane run shown in FIG. 1; FIG. 3 is a schematic view of a second embodiment of a paper web processing unit of the present invention; and FIG. 4 is a schematic view depicting an alternate embodiment of an upper felt transfer section shown in FIG. 3 . 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 more particularly to FIG. 1, there is shown an air press assembly 10 including a felt 12 for carrying a continuous fiber web 13 , a plurality of rolls 14 - 20 , a tension roll 22 , a guide roll 24 , and a membrane 26 . Plurality of rolls 14 - 20 are arranged for cooperative rotation and include a first press roll 14 , a second press roll 16 , a first cap roll 18 , and a second cap roll 20 . First press roll 14 is opposed to and spaced apart from second press roll 16 , and first cap roll 18 is opposed to and spaced apart from second cap roll 20 . First cap roll 18 and second cap roll 20 each are positioned adjacent to and form roll nips 28 - 34 , respectively, with each of first press roll 14 and second press roll 16 . First cap roll 18 is smaller in diameter than second cap roll 20 . By having such a relatively small diameter, first cap roll 18 may more easily create a sealing engagement with first press roll 14 and second press roll 16 at roll nips 30 and 32 , respectively. Forming such a sealing engagement is important when a pressurized fluid, such as compressed air, is injected (not shown) into a space 33 between rolls 14 - 20 of air press assembly 10 . The pressure created thereby may be selected depending on the specific application and, e.g., may be about 100 psig. Rolls 14 - 20 each can be one of a crown compensating, shoe, swimming, or piston type roll. Rolls 14 - 20 are preferably crown compensating rolls since crown compensating rolls are structured and arranged to prevent deflection at the center of the rolls. By preventing deflection at the center of the rolls, leakage between the rolls due to such deflection is likewise minimized, if not prevented. Such deflection, if not compensated for, can otherwise act as a significant leakage source at roll nips 28 - 34 since rolls 14 - 20 are usually 3 ft. to 40 ft. long and consequently may be prone to sagging. In the preferred embodiment shown in the drawings, second cap roll 20 is a crown compensating roll. Crown compensating roll 20 has an outer roll surface 36 , and the section of outer roll surface 36 between roll nips 28 and 34 has been labeled as nip line 38 . Since second cap roll 20 is crown compensating, a seal may be maintained between outer roll surface 36 and membrane 26 along nip line 38 . This crown compensation helps counter the effect of gravity, which tends to cause second cap roll 20 to pull away from mating rolls 14 and 16 . This gravitational effect is not as critical for first cap roll 18 , which actually rests along its length upon rolls 14 and 16 . Broadly stated, it is preferable that at least the lowermost positioned roll within air press assembly 10 is crown compensated due to such gravitational effects. Tension or stretch roll 22 is movable in a first direction 40 (shown schematically in FIG. 1) extending toward and away from plurality of rolls 14 - 20 . Such movement of tension roll 22 is generated by a first position controller 42 (FIG. 2 ). Guide roll 24 is pivotable about an axis in first direction 40 and is movable in second direction 44 extending transverse to plurality of rolls 14 - 20 . Such movement of guide roll 24 is controlled by a second position controller 46 . Guide roll 24 is shown to be cylindrical in the drawings. However, the outer longitudinal surface of guide roll 24 may be any one of cylindrical, convex, or concave, based upon necessary design criteria. Second position controller 46 is operatively connected to a membrane position sensor (S) 47 . Membrane position sensor 47 detects a lateral position of membrane 26 upon second cap roll 20 . Membrane position sensor 47 may be any one of various types of position sensors, including, but not limited to, opto-electronic, inductive, mechanical, and sonic type sensors. Membrane 26 is positioned so as to wrap around and be in movable contact with both second cap roll 20 , tension roll 22 and guide roll 24 . Membrane 26 is preferably semipermeable so that it conveys a certain amount of air into nip 28 between second cap roll 20 and first press roll 14 . As membrane 26 becomes compressed by rolls 14 and 20 at nip 28 , the air trapped within membrane 26 is forced outward and thereby pushes moisture into felt 12 carrying paper web 13 . Thus, membrane 26 and rolls 14 and 20 coact in a manner similar to a piston. An additional effect of this air compression is that it tends to force felt 12 and paper web 13 away from membrane 26 and onto first press roll 14 , opposing membrane 26 . This effect helps felt 12 and paper web 13 achieve the proper feed path upon entering air press assembly 10 . Tension roll 22 is positionable in first direction 40 so as to maintain tension in membrane 26 and thereby avoid a slack run. A slack run of membrane 26 could damage both membrane 26 itself as well as fiber web 13 . Additionally, guide roll 24 is stationed so as to be in coacting contact with membrane 26 . Preferably, guide roll 24 is in contact with inner membrane surface 48 . Alternatively, guide roll 24 instead contacts outer membrane surface 50 (shown in phantom in FIG. 1 ). It is preferable to employ a membrane 26 of an increased length since an increased membrane length allows longer membrane life. The increased membrane life is possible since any given length of a longer membrane 26 would spend less time in roll nips 28 - 34 during a revolution of membrane 26 than the same given length of a shorter membrane. The increased length of membrane 26 is accommodated by the combined presence of tension roll 22 and guide roll 24 . Tension roll 22 and guide roll 24 in conjunction with second cap roll 20 can generate an extended path over which membrane 26 may travel. During the operation of air press assembly 10 , fiber web 13 is fed into roll nip 28 and is conveyed along a section of first press roll 14 which faces second press roll 16 until reaching roll nip 30 . Upon reaching roll nip 30 , fiber web 13 is carried on a section of first cap roll 18 which generally faces away from plurality of rolls 14 - 20 . Once fiber web 13 enters roll nip 32 , fiber web 13 travels along a section of second press roll 16 which faces first press roll 14 and remains in contact therewith until after exiting through roll nip 34 . Concurrent with the feeding of fiber web 13 through plurality of rolls 14 - 20 , membrane 26 is conveyed around second cap roll 20 and tension roll 22 and against guide roll 24 . Membrane 26 interacts with fiber web 13 at roll nips 28 and 34 . During operation, membrane 26 has a tendency to meander back and forth along the length of second cap roll 20 . In fact, use of a longer membrane as per this invention tends to magnify the effect of the natural tendency of a membrane to oscillate laterally along a roll through multiple membrane cyclings. This tendency is offset by sensing a position of membrane 26 using membrane position sensor 47 and, as necessary, adjusting the pivot angle of guide roll 24 using second position controller 46 to counteract the tendency to meander and thereby generally laterally center membrane 26 on second cap roll 20 . Guide roll 24 may further be moved in second direction 44 by second position controller 46 , for example, to optimize the membrane centering capability thereof or to ease a changeover of membrane 26 . A second embodiment of the present invention, shown in FIG. 3, depicts a schematic system view of a paper web processing unit 60 . Paper web processing unit 60 includes an upper felt run 62 , a lower felt run 64 , an air press assembly 66 , and a transfer device 68 . Upper felt run 62 includes an upper felt 70 and a plurality of rolls 72 - 82 . At least one of rolls 72 - 82 is mounted to a drive shaft (not shown) in order to power movement of upper felt 70 in first travel direction 84 through upper felt run 62 . In the embodiment shown in FIG. 3, roll 74 is a guide roll movable about pivot direction 86 , while roll 78 is a stretcher roll movable in second direction 88 , which is essentially equivalent to second direction 44 in the first embodiment. Roll 82 is a pick-up roll, also movable in second direction 88 . Alternatively associated with upper felt run 62 adjacent to pick-up roll 82 is a transfer box 90 , shown in FIG. 4 . Transfer box 90 applies a vacuum to paper web 92 and lower felt 94 to ensure that paper web 92 remains on lower felt 94 and is not transferred upward along with upper felt 70 by pick-up roll 82 after upper felt 70 , paper web 92 and lower felt 94 have passed through and beyond air press assembly 66 . Lower felt run 64 includes a lower felt 94 , plurality of rolls 96 - 106 , cleaning showers 108 , Uhle boxes 110 and lube showers 112 . Rolls 96 - 106 include at least one roll which is mounted to a drive shaft (not shown) in order to power movement of lower felt 70 in second travel direction 114 through lower felt run 64 . In the embodiment shown in FIG. 3, roll 98 is a guide roll movable in pivot direction 116 , and roll 104 is a guide roll movable in pivot direction 118 . Roll 102 is a tension roll movable in second direction 88 . Cleaning showers 108 , Uhle boxes 110 , and lube showers 112 are provided to maintain lower felt 94 . Cleaning showers 108 rinse out of lower felt 94 residual paper fibers and chemicals which may remain from a previous paper web transfer cycle. Uhle boxes 110 condition lower felt 94 between transfer cycles. Lube showers 112 are used to keep lower felt 94 lubricated when paper web processing unit 60 is not in a production mode. Transfer device 68 includes a suction pick-up roll 120 and a transfer membrane 122 . Transfer device 68 is positioned downstream from air press assembly 66 and is configured for moving paper web 92 , now densified upon passing through air press assembly 66 , onto a next part of the paper-making process. Air press assembly 66 is as substantially described previously in relation to the first embodiment shown in FIGS. 1 and 2. Air press assembly 66 includes rolls 124 - 134 and membrane 136 , which correspond and function similar to rolls 14 - 24 and membrane 26 . During operation of paper web processing unit 60 , paper web 92 is introduced between upper felt 70 and lower felt 94 at web entry point 138 . Paper web 92 is then conveyed along with upper felt 70 and lower felt 94 through air press assembly 66 , where paper web 92 is densified. Upon exiting air press assembly 66 , upper felt 70 is directed away from paper web 92 and lower felt 94 at roll 82 . At the next proceeding station downstream of air press assembly 66 , densified paper web 92 is suctioned off of lower felt 94 by suction pick-up roll 120 and transported to a next part of the paper-making process by transfer membrane 122 . Lower felt 94 continues on through lower felt run 64 . 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.
A device for processing a continuous fiber web includes a membrane, a pressurized enclosure, a tension roll and a guide roll. The pressurized enclosure includes at least a first roll and defines an air press chamber. The first roll partially defines the air press chamber and carries the membrane. The tension roll also carries the membrane and is movable toward and away from the first roll. The guide roll further carries the membrane and is positioned between the first roll and the tension roll. The guide roll has opposite ends, at least one of which is pivotable toward and away from the first roll.
3
BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a method for improving the quality of abrasive grains of Al 2 O 3 comprising titanium oxide, preferably Ti 2 O 3 , whereby a ceramic coating is applied, e.g. melted and/or sintered, onto the abrasive grain. The invention also relates to the treatment of conventional abrasive grains of molten or sintered electrocorundum, which are commercially available as normal corundum or microcrystalline corundum and contain between 0.5 and 5.0 weight percent of titanium oxide (Ti 2 O 3 and TiO 2 ), the chief constituent being Ti 2 O 3 . 2. Description of the Prior Art Corundum, which is to be used as an abrasive means in abrasive articles, such as abrasive disks, is, according to prior art methods, occasionally annealed at a temperature of about 1350° C., whereby the grain structure is changed and the abrasive properties are improved. This treatment shows in the blue colour which the corundum takes on in the course of this treatment. It is further known in the art to provide corundum grains with a coating, e.g. of ceramic materials and ferric oxides, producing an improved adhesion between the abrasive grain and the bond in the abrasive article resp. having filler properties and taking an active part in the abrasive process, e.g. by improving the heat removal. In prior art methods the abrasive grain is annealed and coated in two separate operating cycles. First the abrasive grain is heated in oxidizing atmosphere to a temperature of about 1350° C. until it takes on blue colour and then the abrasive grain is cooled off again to room temperature. After cooling off, a ceramic coating is applied onto the abrasive grain in a separate operating cycle, said coating being based on phosphates or silicates with low-melting, ceramic frits (glass frits) and fine ground metallic oxides--preferably Fe 2 O 3 for cost saving reasons. For this purpose the abrasive grain is heated again to a temperature of about 600° C. to 800° C. The thus obtained coating creates a greater surface and a better surface wettability due to its rough, granular surface structure. Consequently, a greater and improved adhesive surface is provided for the resinoid bond of the abrasive article, whereas the adhesion between the abrasive grain and the coating is frequently not as intense as required. When abrasive grains treated in the above-described manner are inserted into the abrasive article, grains break off easily, which have not or only insufficiently been utilized in the abrasive process, particularly in the case of abrasive disks of high density. A further reason for the breaking off of abrasive grains is the porous and relatively thick (15-50 μm) coating itself which is only of low strength. The liquid constituent of the resinoid bond is not always able to soak the thick coating entirely, i.e. to its bottom. Therefore, the porous coating itself forms a preferred fracture zone in the course of subsequent stress. Even if good adhesion is obtained between the coating and the grain and between the coating and the bond, the coating itself can be torn, whereby one part of the coating adheres to the grain, and the other part adheres as corresponding part to the binding material of the abrasive article. SUMMARY OF THE INVENTION The above-mentioned annealing process, i.e. the heating of the abrasive grain to a temperature of about 1350° C., alters the fracture behaviour and the strength properties of the abrasive grain and increases the abrasive capacity of the finished abrasive tool. It also guarantees a cooler grinding. The change from brown into blue and the modified mechanical properties are due to the change of the titanium from the trivalent into the quadrivalent degree of oxidation. A maximum of 5% by weight of titanium in the form of oxides (particularly Ti 2 O 3 ) is contained in the abrasive grain of the present invention. This rise in the degree of oxidation from Ti 3+ to Ti 4+ effects the "precipitation" of the Ti 2 O 3 , which is "dissolved" in the Al 2 O 3 in the form of TiO 2 . It is the object of the present invention to provide a method in which the annealing process, which effects the change in the grain structure, and the coating of the grain, e.g. with a layer improving adhesion, are carried out in one operating cycle and which allows a reduction in the consumption of energy. According to the invention this is achieved by exposing the abrasive grain to a temperature between 1250° and 1350° C. over a period of between 15 minutes and 2 hours, whereby the ceramic coating is sintered resp. melted onto the abrasive grain simultaneously with the change of the Ti-oxides from the trivalent into the quadrivalent degree of oxidation, and thus simultaneously with the change in the grain structure. The coating of the abrasive grain treated in accordance with the method of the present invention has a thickness of only 2-5 μm. Said coating is characterized by an extremely great adhesion to the grain surface and great internal strength, which is due to an intermediate layer made of spinel, for example. Apart from the energy-saving effect as compared to conventional methods, the coating applied onto the abrasive grain in accordance with the present invention has the great advantage of an extraordinary adhesion to the grain, high internal strength and reduced thickness. DESCRIPTION OF THE PREFERRED EMBODIMENTS It is preferably provided that the period of the heat treatment lies between 20 minutes and 45 minutes. It is further preferably provided that the coating materials are silicates, clay, kaolin and/or high-melting glass frits. A further preferred embodiment of the present invention provides that metallic oxides, e.g. ferric oxides and/or manganese oxides and/or chromium oxides, are admixed to the coating material resp. contained therein. At burning temperatures of between 1250° and 1350° C. the controlled use of metallic oxides effects the separation of oxygen in accordance with the following example: MeO.sub.2 →MeO+1/2O.sub.2 In the present embodiment the oxygen is always set free immediately at the grain surface, and consequently the oxidation of the trivalent titanium is considerably accelerated by the nascent oxygen. This additional oxygen supply allows a reduction of the burning period by up to 50% as compared to conventional annealing methods. It is preferably provided that the metallic oxide constituent amounts to about 1-5% by weight referred to the amount of abrasive grain. A further embodiment of the present invention provides that substances, e.g. ZrO 2 , are admixed to the coating material, which have a coefficient of expansion varying from the coefficient of expansion of the ceramic material (and the abrasive grain) as much as possible. By adding zirconium corundum, for example, whose high thermal change in volume, when being cooled off after the burning process, produces a fine mesh of microcracks, a greater coating surface and an increase in the tensile- and bending strength of the coating and, thus, occasionally of the abrasive grain, are obtained, as said microcracks prevent the formation of great cracks. A particularly preferred embodiment of the present invention in which the adhesion between the abrasive grain and the resinoid bond of the abrasive disk is substantially improved provides that between 0.5 and 1.5 weight percent, preferably 1.1 weight percent, of SiC referred to the amount of grain are admixed to the coating material. Said admixture effects that the SiC decomposes resp. oxidizes already at temperatures from 900° C. onwards. An optimum degree of decomposition is obtained at the temperatures applied in the treatment of the grain in accordance with the present invention, i.e. 1250°-1350° C. Gaseous carbon dioxide resp. carbon monoxide and SiO resp. SiO 2 are produced in the course of said decomposition, whereby the gaseous carbon oxides create blisters in the molten material of the coating. Said blisters produce an obvious improvement in the coating surface and, consequently, an increased external adhesive surface on the abrasive grain and an improved adhesion of the coated abrasive grain in the binding material. In accordance with the present invention the following substances, either alone or in mixtures, are, for example, used as a coating material: ______________________________________Kaolin, Glass frits,preferably composed preferably composedas follows as follows______________________________________annealing loss 13,0% by weight in generalSiO.sub.2 46,6 by weight SiO.sub.2 45-70% by weightAl.sub.2 O.sub.3 37,8 by weight Al.sub.2 O.sub.3 7-15 by weightFe.sub.2 O.sub.3 0,6 by weight B.sub.2 O.sub.3 0-25 by weightK.sub.2 O 1,0 by weight MgO 0-3,5 by weightNa.sub.2 O 0,2 by weight CaO 0-7 by weightCaO 0,3 by weight Na.sub.2 O 0-5 by weightMgO 0,2 by weight K.sub.2 O 0-12 by weightTiO.sub.2 0,3 by weight P.sub.2 O.sub.5 0-6 by weight______________________________________Clay,preferably composed Clays containingas follows manganese oxides,______________________________________ MnO.sub.2 12-15% by weight SiO.sub.2 25-30 by weightSiO.sub.2 63-70% by weight Al.sub.2 O.sub.3 14-16 by weightAl.sub.2 O.sub.3 25-27 by weight Fe.sub.2 O.sub.3 25-28 by weightTiO.sub.2 0,6-0,7 by weight CaO 0,6 by weightFe.sub.2 O.sub.3 0,5-0,6 by weight MgO 0,2 by weightNa.sub.2 O 0,6-0,7 by weight K.sub.2 O 2,5 by weightK.sub.2 O 0,9-1,0 by weight Na.sub.2 O______________________________________Clays containing ferric oxides,______________________________________SiO.sub.2 58,0% by weightAl.sub.2 O.sub.3 19,8 by weightFe.sub.2 O.sub.3 8,1 by weightCaO 0,1 by weightMgO 0,1 by weightK.sub.2 O 5,3 by weightNa.sub.2 O 3,5 by weightannealing loss 4,6 by weight______________________________________ Further coating materials used in accordance with the present invention are phosphates, borates and silicates, which are applied individually or in a mixture. When applying the coating material onto the grain surface in accordance with the present invention it has proved advantageous to moisten the abrasive grain. The following wetting agents are used by the present invention: aqueous solutions of silicates, phosphates and borates, phosphoric acids, boric acids, silicic acids, organic Si-compounds, such as ethyl- and methyl polysiloxane. It is essential to choose coating and wetting materials which are suitable for producing on the abrasive grain a rough, macroscopically closed coating which sporadically contains the above-mentioned microcracks. It is further essential that in spite of the high temperatures during the heat treatment no undesired intense edge corrosion occurs on the abrasive grain, which would considerably deteriorate its abrasive properties. A slight surface etching of the abrasive grains is indispensable, however, as such etching allows the formation of a chemical layer (cf. drawing). The wetting agents have to be used in suitably low concentrations. In the following five embodiments of the present invention will be described: The FIGURE of the drawing shows in accordance with embodiment 4 the abrasive grain 1 (normal corundum, Al 2 O 3 ), an adjacent galaxite intermediate layer MnAl 2 O 4 2 and a sintered layer of manganese oxide grains 3 in a glass matrix 4. The intermediate layer 2 forms a chemical as well as a mechanical bond with the corundum 1 and the actual coating layer 3. Microcracks due to ZrO 2 , for example, are shown by the number 5. The FIGURE of the drawing shows a schematic sectional view of the boundary layer of an abrasive grain. ______________________________________Embodiment 1:Al.sub.2 (normal corundum) ≈ 700 μm 96,5% by weightWetting agent, as mentioned 1,0 by weightKaolin (grain size < 5 μm) 1,1 by weightAl.sub.2 O.sub.3 (grain size < 10 μm) 1,4 by weightEmbodiment 2:Al.sub.2 O.sub.3 (normal corundum) ≈ 700 μm 96,45% by weightWetting agent, as mentioned 1,3 by weighthigh-melting frit < 38 μm 1,25 by weightMnO.sub.2 (grain size < 10 μm 2,0 by weightEmbodiment 3:Al.sub.2 O.sub.3 (normal corundum) ≈ 700 μm 95,5% by weightWetting agent, as mentioned 1,3 by weightClay < 5 μm 1,2 by weightMnO.sub.2 < 10 μm 2,0 by weightEmbodiment 4:Al.sub.2 O.sub.3 (normal corundum) ≈ 700 μm 95,55% by weightWetting agent, as mentioned 1,2 by weightFrit (grain size < 38 μm) 1,25 by weightMnO.sub.2 (grain size < 10 μm) 1,8 by weightZrO.sub.2 (grain size < 10 μm) 0,2 by weightEmbodiment 5:Al.sub.2 O.sub.3 (normal corundum) ≈ 700 μm 96,8% by weightWetting agent, as mentioned 1,0 by weightKaolin (grain size < 5 μm) 1,1 by weightSiC (grain size < 20 μm) 1,1 by weight______________________________________ Preferably after being moistened the abrasive grain is mixed with the fine ground coating material in a conventional mixer. It is then coated and subsequently burned in a rotary tubular kiln at a temperature of between 1250° C. and 1350° C., whereby the heat treatment should not exceed 2 hours and last over a period of between 20 and 45 minutes, for example. In order to find out the influence of the treatment of the abrasive grain on the strength behaviour of a finished abrasive article, specimens of the below-indicated composition were made. Their dimensions were 120×10×15 mm for testing the bending yield strength and 10×10×15 mm for testing the compressive yield strength. They were compressed to a compressive density of d o =. . . 2,79. ______________________________________Grain size ≈ 700 μm 50% by volumePhenolic resin (solid:liquid =4:6) 30% by volumeFiller (cryolite) 15% by volume(Pores) 5-10 by volume______________________________________ Hardening was carried out at a temperature of 190° C. over 54 hours. Specimens (severing disks--400×45×32 mm) composed as indicated above were made of untreated, conventionally annealed and coated normal corundum and of normal corundum treated in accordance with the present invention and then tested. In the tests round profiles φ 30 mm of constructional steel were severed. The results obtained in these comparative tests are listed in the following table: ______________________________________ Bending yield Compressive strength yield strength G-factorGrain kN/mm.sup.2 kN/mm.sup.2 Abrasive ratio______________________________________untreated normalcorundum 5200 13 300 3,0conventionallycoated andannealed normalcorundum 6000 16 600 3,7normal corundumtreated in accor-dance with thepresent invention 7100 17 300 4,1______________________________________ G-factor = Ratio between severed crosssectional work piece surface and worn disk surface (disk abrasion)
Abrasive grain, corundum (Al 2 O 3 ) comprising titanium oxide, preferably Ti 2 O 3 , is provided with a ceramic coating. The abrasive grain is subjected to a heat treatment whereby the Ti-oxides change from the trivalent into the quadrivalent degree of oxidation. The coating and the change of the degree of oxidation are effected simultaneously.
2
FIELD OF THE INVENTION The present invention relates to electronic returnless fuel delivery systems, and more particularly, to controlling a fuel pump in an electronic returnless fuel delivery system. BACKGROUND OF THE INVENTION Conventional control strategy for an electronic returnless fuel delivery system for an internal combustion engine typically comprises a series of calculations aimed at obtaining the proper quantity of fuel to be delivered to the engine with little or no fuel returned to the fuel tank. Typically, a mass air flow sensor is installed in the air intake system at an upstream position of a throttle valve to accurately detect the mass air flow rate of the air into the engine. An engine controller then manipulates the sensed mass air flow using a physically based manifold filling model, which takes into account parameters such as engine displacement, manifold volume and volumetric efficiency, to determine the air charge entering the engine's combustion chambers. Once this cylinder air charge is calculated, the corresponding desired fuel charge is computed based on a desired air/fuel ratio and manifold absolute pressure (MAP). The controller then calculates a desired feedforward (open loop) fuel pump voltage so the pump may supply fuel to the fuel rail at a desired pressure. The controller also calculates a desired fuel injection pulsewidth based on the difference between fuel rail pressure and MAP. This sequence of events, however, assumes a steady state condition between the time the mass air flow is first measured at the mass air flow sensor to the time the feedforward voltage signal is communicated to the fuel pump. In a transient engine operating condition, however, such as a "tip-in" or "tip-out", which is herein defined as a rapid throttle positional change such as a rapid opening and closing of the throttle valve, respectively, the desired feedforward fuel pump voltage is no longer valid. This is because the feedforward fuel pump voltage calculations are performed asynchronously with, and much less frequently than, the cylinder air charge calculations. Any attempt to perform the desired feedforward fuel pump voltage calculations at the same time and speed as the cylinder air charge calculations would slow the engine controller down such that its ability to control other engine systems would be impaired. Typically, during such a transient condition, the fuel rail pressure departs from a desired value due, in part, to the need to rely upon obsolete values of the desired feedforward fuel pump voltage. In addition to the above mentioned feedforward voltage calculations, prior electronic returnless fuel systems may employ feedback correction calculations. Because the fuel injector pulsewidth is calculated based on the difference in pressure between the fuel rail pressure and MAP, any departure from the desired fuel rail pressure results in a fuel rail pressure error, which must occur before a feedback error correction voltage is added to or subtracted from the desired feedforward fuel pump voltage so the pump may increase or decrease fuel rail pressure accordingly. As a result, during transient engine operating conditions, because the air charge to the cylinder can change within one cylinder event, the engine may operate in either a rich or a lean condition prior to the feedback control correcting the voltage to the fuel pump. SUMMARY OF THE INVENTION An object of the present invention is to provide an engine with a proper amount of fuel during transient operating conditions. This object is achieved and the disadvantages of prior art approaches are overcome by providing a novel method for controlling an electronically powered fuel pump in an electronic returnless fuel delivery system for an internal combustion engine during a transient engine operating condition. In one particular aspect of the invention, the method includes the steps of sensing an engine operating parameter for a first time, sensing the engine operating parameter for a second time, and inferring whether a transient engine operating condition occurred between the first and second times by comparing the difference in engine operating parameters between the first and second times and determining whether the comparison is above a threshold level. Next, the method includes the step of generating an estimate of a fuel pump correction signal based on this inference. The correction signal has a value proportional to the magnitude of the compared difference and is generally sufficient to cause the fuel pump to respond to the transient condition by supplying a generally correct amount of fuel to the engine prior to the engine requiring a change in fuel quantity, thereby allowing the engine to suitably respond to the transient condition. In a preferred embodiment, the sensed engine operating parameter is desirably one that is sensed often and sensed asynchronously with respect to feedforward fuel pump voltage calculations. Accordingly, the sensed engine operating parameter may be mass air flow or throttle position. An advantage of the present invention is that a generally correct amount of fuel is supplied to the engine. Another, more specific, advantage of the present invention is that a generally correct air/fuel ratio is maintained during transient engine operating conditions. Still another advantage of the present invention is that fuel is delivered to the engine at a correct pressure. Yet another advantage of the present invention is that regulated emissions are reduced. Other objects, features and advantages of the present invention will be readily appreciated by the reader of this specification. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described, by way of example, with reference to the accompanying drawings, in which: FIG. 1 is a block diagram of a fuel delivery system incorporating the present invention; FIGS. 2 and 3 are flow charts describing various operations performed by the present invention; and, FIG. 4 is a schematic representation of a control system according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Internal combustion engine 10, comprising a plurality of cylinders, one of which is shown in FIG. 1, is controlled by electronic engine controller 12. Engine 10 includes combustion chamber 20 and cylinder walls 22. Piston 24 is positioned within cylinder walls 22 with conventional piston rings and is connected to crankshaft 26. Combustion chamber 20 communicates with intake manifold 28 and exhaust manifold 30 by respective intake valve 32 and exhaust valve 34, respectively. Intake manifold 28, communicating with throttle 36, includes fuel injector 38 coupled thereto for delivering fuel in proportion to a signal received from controller 12. Fuel is delivered to fuel injector 38 by electronic returnless fuel delivery system 40, which comprises fuel tank 42, electric fuel pump 44 and fuel rail 46. According to the present invention, fuel pump 44 pumps fuel at a pressure directly related to the voltage applied to fuel pump 44 by controller 12. In this particular example, a separate fuel injector for each engine cylinder (not shown) is coupled to fuel rail 46. Also coupled to fuel rail 46 are fuel temperature sensor 50 and fuel pressure sensor 52. Pressure sensor 52 senses fuel rail pressure relative to manifold absolute pressure (MAP) via sense line 53. Controller 12, shown in FIG. 1, is a conventional microcomputer including microprocessor unit 102, input/output ports 104, electronic storage medium for storing executable programs, shown as "Read Only Memory" chip 106, in this particular example, "Random Access Memory" 108, and a conventional data bus. Controller 12 receives various signals from sensors coupled to engine 10, in addition to those signals previously discussed, including: measurement of mass air flow from mass air flow sensor 58, engine temperature from temperature sensor 60, a profile ignition pick-up signal from Hall effect sensor 62, coupled to crankshaft 26, intake manifold absolute pressure (MAP) from pressure sensor 64 coupled to intake manifold 28, and position of throttle 36 from throttle position sensor 66. As previously stated, fuel charge is determined through a series of calculations performed by controller 12. According to the present invention, controller 12 infers that a transient condition is occurring by determining an increase or decrease in mass air flow sensed by sensor 58. Controller 12 then adjusts voltage to pump 44 based on this inference to compensate for any subsequent increase or decrease in fuel as will be fully described hereinafter. Referring in particular to FIG. 2, controller 12 determines whether or not engine 10 is running, shown at step 200, because it may be undesirable to adjust the voltage to the pump during engine start. Accordingly, if the engine is cranking, fuel pump voltage adjustment (also herein referred to as voltage trim logic) is disabled, as shown at step 202. On the other hand, if engine 10 is running (not in a cranking mode), controller 12 next determines whether mass air flow sensor 58 is functioning. If mass air flow sensor 58 is not functioning, the voltage trim logic is disabled at step 202. If, on the other hand, mass air flow sensor 58 is functioning, the voltage trim logic is enabled, as shown in step 206. Next, at step 208, controller 12 determines the cylinder air charge (A) first by sensing the mass air flow sensed by sensor 58, then by manipulating the sensed mass air flow using a physically based manifold filling model known to those skilled in the art and suggested by this disclosure. At step 209, controller 12 may record throttle position (TP). Proceeding from step 209, at step 210, controller 12 obtains MAP either through sensor 64 or, in an alternative embodiment, by inferring MAP by methods known to those skilled in the art and suggested by this disclosure. MAP is needed because fuel pressure in fuel rail 46 is maintained at a desired level relative to MAP, typically 40 psi above MAP, through sense line 53. Accordingly, it is desirable to maintain the 40 psi pressure above manifold absolute pressure in the fuel rail 46 by controlling fuel pump 44. During a transient condition (either a "tip-in" or "tip-out"), one of the first sensors to respond is mass air flow sensor 58. A time lag exists between the time when mass air flow sensor 58 records air flow through throttle valve 36 and the time when the feedforward fuel pump voltage calculations are performed and a feedforward voltage signal is sent to fuel pump 44 to allow fuel pump 44 to respond accordingly. Attaining the proper fuel rail pressure is also delayed because of the time required to pressurize the system. However, because MAP responds relatively quickly to the change in mass air flow, the fuel rail pressure to which fuel pump 44 had been pumping to maintain the 40 psi pressure differential is no longer valid due to this relatively slow fuel pump control logic response. Further, in feedback systems, an error must occur prior to any subsequent corrective action. According to the present invention, controller 12 infers that a transient condition is occurring and adjusts the fuel pump voltage so that the fuel rail pressure may be maintained at the desired level above MAP prior to the engine requiring a change in fuel quantity as indicated by, for example, a feedback error signal from either fuel pressure sensor 52, MAP sensor 64, or inferred MAP, or by recalculating a new feedforward fuel pump voltage, thereby eliminating the aforementioned time lag. The way this is accomplished is best explained with reference to FIGS. 3 and 4. At step 220, controller 12 records an anticipated air charge (A 1 ), which is the present sensed mass air flow sensed by mass air flow sensor 58. Controller 12 may also record a new throttle position (TP 1 ), as shown at step 221. At step 222, controller 12 calculates the percentage difference (Δ) between the cylinder air charge (A) recorded prior at step 208 and the anticipated air charge (A 1 ) recorded presently at step 220 or the percentage difference (Δ) between the TP recorded prior at step 209 and TP 1 recorded presently at step 221. Thus, in an alternative embodiment, Δ may be calculated from present and prior positions of throttle 26 as sensed by throttle position sensor 66. Of course, as previously stated, sensed mass air flow may be used directly instead of the calculated cylinder air charge (A, A 1 ). At step 224, Δ is compared to a threshold level to infer that a transient has occurred. At step 225, the present pump voltage (V p ) is multiplied by Δ to get the new fuel pump voltage (V p '). This is all accomplished prior to the cylinder air charge (A) reaching combustion chamber 20. The air/fuel ratio first calculated is still used, however, the voltage to pump 44 is adjusted, according to the present invention, so that the proper fuel pressure will be available at fuel rail 46 when engine 10 must respond to the transient condition. For the sake of completeness, an increase in demand for fuel, for example, may be supplied to combustion chamber 20 by injecting an additional amount of fuel into combustion chamber 20, increasing the fuel injector pulsewidth, or other methods known to those skilled in the art and suggested by this disclosure as desired. In a preferred embodiment, it may be desirable to obtain a new MAP which will likely occur based on the inference that a transient condition is occurring. That is, at step 226, controller 12 multiplies MAP obtained at step 210 by Δ to get a new operating manifold absolute pressure (MAP 1 ). Controller 12 then, at step 226, multiplies MAP 1 by a conversion factor (C f ) to obtain a voltage trim (V t ) for the fuel pump. At step 228, the voltage trim (V t ) is added to the present fuel pump voltage (V p ) to obtain a new fuel pump operating voltage (V p '). FIG. 4 is a schematic representation of the control system according to the present invention. When a transient occurs, the desired fuel rail pressure changes within milliseconds, as shown at 232. Ideally, the actual fuel rail pressure would respond in a similar step manner, shown at 234. However, this ideal response is delayed in a fuel rail pressure control strategy that depends solely on feedforward and feedback voltage, as shown at 236. Due to computational lags, the feedforward voltage calculation, which is a step function, shown at 238, occurs at a later point in time. Further, should the fuel rail pressure not be at a desired pressure, the feedback voltage, shown at 240, is added to the fuel pump voltage. While this feedback voltage further refines the fuel pump output so as to attain the desired fuel rail pressure, it also has inherent lags. According to the present invention, a voltage trim adjustment, shown at 242, is also added to the fuel pump voltage to reduce the effects of the aforementioned time lags. This results in the output (fuel rail pressure) approaching the ideal output of 232, as shown at 244. As previously stated, the voltage trim is a function of a sensed engine operating parameter such as mass air flow or throttle position. Thus, according to the present invention, controller 12 controls fuel pump 44 (FIG. 1) such that fuel pump 44 is driven to a different operating state prior to engine 10 responding to the transient condition such that when engine 10 responds to this transient condition, adequate fuel pressure is available at fuel rail 46. That is, fuel pump 44 is commanded to operate to a different operating level based on an inference that a transient condition is occurring. While the best mode for carrying out the invention has been described in detail, those skilled in the art in which this invention relates will recognize various alternative designs and embodiments, including those mentioned above, in practicing the invention that has been defined by the following claims.
An electrically powered fuel pump in an electronic returnless fuel delivery system for an internal combustion engine is controlled during transient engine operating conditions. A controller senses an operating parameter to infer whether a transient engine operating condition exists. Then, the controller generates an estimate of a fuel pump correction signal based on this inference. The correction signal is generally sufficient to cause the fuel pump to respond to the transient condition, by supplying a generally correct amount of fuel, prior to the engine requiring a change in fuel quantity.
5
BACKGROUND AND SUMMARY OF THE INVENTION The present invention has as an object to provide a press for the automatic ironing and finishing of trousers. The present invention represents a brand new automatic-press machine in the field of the ironing machines, because there does not exist in the current market a machine that can iron trousers automatically. And more precisely, the types of ironing machines presently on the market in this field can only iron the legs of a pair of trousers. They can not iron the full side of a pair of trousers, namely, the waist, the pelvis, the pockets and the crotch. Usually the ironing of the side of a pair of trousers which is closer to the waist has to be done manually or with the use of special equipment called ironing-pelvis-machines. In any case, the ironing of the pelvis of a pair of trousers is always done separately from the legs, because until today a press has not been built that can operate and iron simultaneously both sides, the pelvis and the legs of a pair of trousers, so that the complete ironing of the trousers can be done with only one phase operation ironing. The purpose of this invention is to build a press that can iron simultaneously both the legs and the waist portion of a pair of trousers. Thus, according to one embodiment, the present invention is comprised substantially by three panels of ironing members, a central panel and two sideways panels that can tighten with a lock like the closure of a book against opposite faces of the central panel. The central panel has a reduced height in comparison to the two sideways panels. The present invention includes also a scaffolding set on top of the three panels which is placed to support a series of mobile elements which insert into the pelvis of the trousers. The mobile elements hold the trousers in a position slightly open and with the folds stretched, during closure and ironing from the two sideways panels. The above mobile series of elements contains two sideways pairs of patterns that can automatically get to the middle point in the folds of the pelvis of the trousers. At the same time, the pelvis will be held open by inflated cushions of the external plates used to support the above mentioned external shapes. On the bases of the scaffolding are three hooks, of which two are fixed and placed side by side a short distance apart, and one which is mobile, intermediate to the other two. The third hook is mobile and is supported by a flowing stem in a horizontal position, and is continually subject to the pressure of a spring that stretches to advance beyond the pairs of the two fixed hooks. A fourth rear hook, lined up and facing the mobile hook of the above mentioned group of three hooks also is provided; this fourth rear hook is retractable and moved by a pneumatic piston with a horizontal axle. As a matter of fact, the front triplet of the hooks and the fourth rear hook are placed to cooperate together to support the trousers when ironing such that the pelvis is placed in tension by the retractable rear hook. Then, the waist of the trousers is placed against the two hooks of the front triplet. And more precisely, the two fixed front hooks are inserted inside the waist to match the front folds of the trousers, while the mobile front hook engages the outside of the waist at a middle point, which usually corresponds with the front flap of the trousers. Once the waist of the trousers has been hooked up by the hooks, the legs of the trousers must be put on the middle panel so that the legs are interposed, from the opposite parts, between the middle panel and the two side panels. At this point, the two sideways pairs of patterns are put down and opened inside of the pelvis of the trousers, so that the two front and rear folds shall be spread. The inflatable cushions applied to the rear patterns will then be inflated so that the pelvis shall be opened. On the upper edge of the middle panel, two padded slabs are disposed, one in the front side and one in the rear side, to adapt respectively to the wedge between the front and rear folds of the pelvis to fill in the emptiness that there is between the folds. Once the trousers have been prepared to be ironed, only a command needs to be given to lock the sideways panels. The side will close the legs of the trousers against the middle panel, while up to the higher side they will close the pelvis of the trousers both, against the pairs of the slabs as previously inflated, placed against the outside of the pelvis, and against the four patterns that have been threaded in to the inside of the pelvis. In order for the triplet of panels to achieve vaporizing and aspiring, they should be able to distribute steam or to drain aria through those surfaces of the three panels that will come in to a reciprocal contact. The front and rear padded slabs, will only be steamed. BRIEF DESCRIPTION OF THE DRAWINGS To more clearly and to better explain the press according to the present invention, the following description follows with reference to the attached Figures. Described herein, however, is only an example which is not, of course, to be interpreted in any way as being restrictive. FIG. 1 shows a perspective representation of the press. FIG. 2 shows a perspective representation of the press opened and loaded with a pair of trousers ready to be ironed. FIG. 3 shows a perspective representation of the press closed and in a position of ironing. FIG. 4 shows a perspective representation of the upper end of the press. FIG. 5 shows in an exploded view, the various means provided to hook the waist of the trousers and to stretch out the folds of the trousers. DETAILED DESCRIPTION OF THE INVENTION With reference to the Figs., the press includes a triplet of upright panels, of which one (1) is fixed and centered between two mobile panels. (2) Panels more precisely, the two mobile panels (2) are pivotable about an upright axle, so that it can open and close simultaneously like a book, closing about the middle panel (1). The middle panel (1) has a height reduced in respect to the mobile panels (2). The mobile panels are moveable by a way of an automatic piston. The press includes also two slabs molded and inflated, placed right on the top side (1a) of the middle panel (1). The front inflated slab (3) is adjusted by a handle with a front grip (3a) which is of an arm of sustain member (3b) that can be slidably disposed inside a horizontal tubular lever (1b), hidden inside the panel (1), aligned with the top side (1a). The rear inflated slab (4) has upright pivoted set (4a) and also is equipped with a lower arm as a support (4b) that can be slidably disposed inside the above mentioned horizontal tubular lever (1b) hidden inside the panel (1). The pivoted set (4a) is employed to get in to the middle from the rear into inside the crotch of the trousers. The front inflated slab (3) is manually removed, while the rear inflated slab (3) is manually removed, while the rear inflated slab (4) advances and retracts through a pneumatic piston (4c). The pivoted set (4a) of the rear inflated slab (4) determines the automatic stopping of the advancement of the slab (4). During the advancement of the inflated slab (4), in fact, its pivoted set (4a) is subject to a gradual turning over to the back as it will increase its degree to wedge on the rear of the crotch of the trousers. When the above said pivoted set (4a) reaches its maximum angle of turning over to the back, a switch is activated which disarms the piston (4c) of the rear slab (4). The press includes also a scaffolding (5) placed over the middle panel (1). The scaffolding (5) supports a series of mobile elements designed to be threaded inside the pelvis of the trousers, so that the pelvis of the trousers is maintained in a position slightly spread and with its folds stretched during the closing of the two mobile panels (2). These mobile elements are in fact able to move in horizontal and upright ways, switched from both pneumatic pistons, so that they can be let down into the waist of the trousers and both spread, so to maintain the waist of the trouser in a position slightly opened and with its folds stretched during closing of the two mobile panels (2). The series of mobile elements are made up of two sideways couples of upright shape, each one is made up from a front shaped member (6) and from a rear shaped member (7), which, once they have been let down into inside the waist (C) of the trousers and then spread, they automatically get in to the middle inside the front folds (A) and the rear folds (P) of the pelvis, respectively, as is most clearly shown in FIG. 2. The shaped members (6 and 7) are supported by slabs (6a and 7a), working along horizontal tracks, being part of a carriage that is working in an upright position in respect to the supporting scaffolding (5). The front shaped members (6) are retractable in respect to the slabs (6a), being foreseen a matching of the type of prismatic between the slabs (6a) and the shapes (6), which are subject continuously to an expulsive pressure from a spring interposed between the slabs (6a) and the shapes (6). The rear shapes (7) are pivoted in respect to the slabs (7a) being foreseen a matching of the type that it turn around between the slabs (7a) and the shaped members (7). The shaped members 7 are subject to a continuously expulsive pressure from a spring interposed between the slabs (7a) and the shaped members (7). As a result of the springs (which can not been seen in the illustrations), the shaped members (6 and 7) are continuously pushed against the cloth of the trousers, so that shaped members (6 and 7) can automatically be set and automatically be centered inside the folds (A and P) of the trousers, keeping them spread during the ironing phase. On the external face of the rear slabs (7a) inflatable cushions (8) which spread the pelvis of the trousers while the shaped members (6 and 7) spread the folds are disposed. On the base of the scaffolding (5) a front triplet of hooks and a fourth rear hook are disposed. The triplet of the front hooks is made up of two fixed hooks (9) spatially arranged such that the front inflated slab (3) is disposed therebetween. The third hook (10), intermediate to the first two hooks, is supported from a horizontal working shaft (10a) which is continuously subject to the pressure of a spring (10b) that advances the third hook (10) into the inside and away from the two fixed hooks (9). The waist of the trousers will go between these three hooks such that the two fixed hooks (9) are engaging the inside of the waist in the proximity of the front folds (A) of the trousers, while the mobile middle hook (10) engages the outside of the waist in a middle point of the trousers. To put the waist of the trousers in a taught position a fourth rear hook (11) must be used in addition to front triplet of hooks (9 and 10). The rear hook (11) is lined up and opposed to the front middle hook (10). The fourth hook (11) is retractable and is operated by a pneumatic piston (11a). This hook (11) is put into the inside of the waist (C) in proximity of the middle point of the waist itself. The waist of the trousers will be put in tension by the retraction of the hook (11). On the front side of the middle panel (1) a mobile staff (12) is placed to support a pneumatic piston (13). The pneumatic piston (13) is operable in upright reciprocating runs to displace a horizontal fork (14) which has clutches extending on the two opposed faces of the middle panel (1). The fork (14) is for attaching to the legs of the trousers and spreading them on the two opposed faces of the middle panel (1). To obtain this result, two pliers (15) are provided on either side of the middle panel (1) to attach to the bottom of the two legs of the trousers. The pliers (15) have an internal (inside) button protuberant, that it can automatically be hooked from the clutches of the fork (14) when the fork runs through the lower side of the trousers. The cycle of the automatic ironing will begin with the use and control of a small central switchboard with a control program providing the function of the press. The control starts after the operator has manually suspended the trousers to the hooks and after the front inflated slab (3) has been put into position. On the central panel (1), the control button is then pushed to start the cycle of ironing the trousers. In the Figs. it is to be noted that all the perforated surfaces allow for distribution of steam or inhale aria. The triplet of panels (1 and 2) are steamed and inhaled, in a sense that it can distribute steam or inhale aria through those surfaces of the three panels that are in mutual contact. The inflated slabs (3 and 4) are only steamed. That means, that, the press is equipped with a system of production of water steam, as well as, it is equipped with a system of inhaling aria. These systems, however, are not described or illustrated because conventional ones can be suitably used. The pipes of the system for steaming and inhaling will reach the inside of the panels (1 and 2), while the inflated slabs (3 and 4) will be linked only to the pipes of steaming the system.
This invention concerns a press for ironing trousers consisting of a triplet of vertical panels between which both the legs and the pelvis of the trousers are ironed, the latter being held open by a series of inflatable slabs and shapes supported by relevant carriages sliding horizontally and vertically with respect to the supporting and guide scaffolding positioned above the triplet of panels.
3
CLAIM OF PRIORITY [0001] This Application is a continuation of U.S. Non-Provisional Application No. 12/268,979, filed Nov. 11, 2008, which claimed priority to U.S. Provisional Application No. 60/987,108, filed Nov. 12, 2007, each of which are incorporated herein by reference. This Application also claims priority under 35 U.S.0 §119(a) to Australian Patent Application No. 2008243218, incorporated herein by reference. BACKGROUND [0002] 1. Field of the Invention [0003] The present disclosure relates to the field of car accessories, specifically a collapsible sun shield to protect the interior surfaces of a motor vehicle from excess heat and/or sun exposure. [0004] 2. Background [0005] Car owners often leave their vehicles parked outside for long periods of time, whether in a parking lot while at work or shopping, or in the driveway of their own homes. Sun exposure for these long periods of time can cause extreme heat in the interior of a vehicle, especially in hot desert climates, and can cause discomfort or even harm to the driver and passengers. Sun exposure can also be very damaging to the vehicle's leather, plastic, and/or vinyl surfaces, causing discoloration or cracking. [0006] Several products are currently on the market for protecting the interior of a car from sun exposure, however none are both convenient and effective in protecting a substantial portion of the interior of a car. For example, COVERCRAFT® sells sun shields that span across the interior of a car windshield, thereby partially blocking the sun's rays depending on the direction of the shield relative to the sun. However, these shields are neither efficient insulators nor effective at protecting the entirety of a car's interior surfaces regardless of the time of day or direction of the sun. COVERCRAFT® also markets exterior covers that must be stretched over the entire vehicle. While these covers solve the problem of protecting the entire interior surface of a car regardless of the direction of the sun, they are bulky, difficult to use, and inconvenient when one is pressed for time. Additionally, when in use these covers are exposed to the outdoor elements, accumulating dirt, dust, bird feces and/or insects. Side window sun shields also exist, such as the one taught in U.S. Pat. No. 5,379,822, however these products can be difficult to use and require multiple units for effectively blocking the entire interior of a vehicle from the sun. [0007] An improvement on the abovementioned devices is described in U.S. Pat. No. 5,114,204, invented by the inventor of the present application. This device is composed essentially of a sheet of cover material supported by a frame that includes elongated arms situated horizontally along the opposite sides of the vehicle interior. However, due to the horizontal orientation and location of these arms, they need to include either a sliding or folding mechanism to allow the cover to be properly deployed in the vehicle interior and to be retrieved from deployment for storage in a relatively compact dimension. Such orientation and location of the support frame also works properly only if the segment of the cover it supports is flat, thus the cover cannot assume the appropriate angular shape needed to reflect the sunlight back out to the windshield, side windows and rear window of the vehicle. In addition, since these opposite elongated arms are not connected to each other, the user of the invention has to reach out to the other side of the vehicle and hold both arms of the cover while the related segment of the cover is slid or folded towards the desired direction, thereby making the cover difficult and cumbersome to use. None of the embodiments of this prior invention provide a systematic, consistent and quick way of folding the cover into a compact dimension for storage, thereby requiring a user to spend an impractical amount of time using and storing the device. [0008] What is needed is a collapsible device that can cover the interior surfaces of a motor vehicle regardless of which direction sunlight is coming from, thereby insulating the interior, preventing excessive increase in temperature and avoiding harmful exposure to the sun's UV rays. The device should provide a systematic, consistent and quick way of folding the device into a compact dimension for storage after its use. It is desirable to have a device that minimizes the number of parts or components required for operation, as well as allows a user to easily deploy and retrieve the device from just one side of a vehicle without reaching to the other side. The device should also be useful without requiring modification of the car interior, such as drilling holes, and other permanent or provisional attachments to the car interior, such as hooks or hanging mechanisms. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 depicts a perspective view of the present device. [0010] FIG. 2 depicts a perspective view of the present device. [0011] FIG. 3 depicts a perspective view of an alternate embodiment of the present device. [0012] FIG. 4 depicts one embodiment of an end of a stabilizing arm of the present device. [0013] FIG. 5 depicts one embodiment of a fastening device of the present device. [0014] FIG. 6 depicts the engagement of a stabilizing arm and a fastening device. [0015] FIG. 7 depicts a perspective view of an alternate embodiment of the present device. [0016] FIG. 8 depicts a partially folded view of one embodiment of the present device. [0017] FIG. 9 depicts a perspective view of an alternate embodiment of the present device. [0018] FIG. 10 depicts an alternate embodiment of an end of a stabilizing arm of the present device. [0019] FIG. 11 depicts an alternate embodiment of a fastening device. [0020] FIG. 12 depicts an alternate embodiment of the engagement of a stabilizing arm and a fastening device. [0021] FIG. 13 depicts a perspective view of an alternate embodiment of the present device. [0022] FIG. 14 depicts a side view of one embodiment of the present device. [0023] FIG. 15 depicts a side view of an alternate embodiment of the present device. [0024] FIG. 16 depicts a perspective view of an alternate embodiment of the present device. [0025] FIG. 17 depicts a close-up perspective view of a portion of the device shown in FIG. 16 . [0026] FIG. 18 depicts a top view of one embodiment of the present device. [0027] FIG. 19 depicts a back view of one embodiment of the present device. [0028] FIG. 20 depicts a perspective view of an alternate embodiment of the present device. DETAILED DESCRIPTION [0029] FIG. 1 depicts a perspective view of the present device 100 . A device 100 can be comprised of a sheet 101 having a front end, a back end, a front section 102 , a middle section 104 , and a rear section 106 . Said sheet 101 can be substantially the same length and width as the portion of the interior of a motor vehicle desired to be covered. A front section 102 can have a first set of rigid arms 108 that can be permanently attached to said sheet 101 substantially perpendicular to the length of the motor vehicle in which a device 100 is to be used. In alternate embodiments, said first set of rigid arms 108 can be removably attached to said sheet 101 so that the sheet 101 can be laundered if needed. Said first set of rigid arms 108 can be spaced apart from each other in a manner that can allow for proper folding and storage of a device 100 . A front section 102 can also have an adjustable steering wheel compartment 110 that can accommodate the height, width and depth of a vehicle steering wheel. An adjustable steering wheel compartment 110 can be comprised of a plurality of slits, the cut edges of which can be coupled with flexible material such that said compartment 110 can adjust to the dimensions of a steering wheel while keeping said steering wheel covered. In the embodiment shown in FIG. 1 , the outer surface of an adjustable steering wheel compartment 110 can be facing the front windshield of a vehicle when in use, thereby deflecting the sun's rays back through said front windshield. [0030] As shown in FIG. 1 , a sheet 101 can be fabric, vinyl, thin plastic, polymer, or any other known and/or convenient flexible material. In other embodiments, and as shown in FIGS. 16 and 17 , a sheet 101 can be made of rigid or semi-rigid material, such as plastic or any other known and/or convenient material. A sheet 101 can be made of a reflective material, insulating material, and/or heat-resisting material. A sheet 101 can also be manufactured in different dimensions so as to accommodate the dimensions of various vehicle models. A first set of rigid arms 108 can be plastic, fiberglass, metal, or any other known and/or convenient rigid material. [0031] A middle section 104 can have a second set of rigid arms 108 that can be permanently attached to said sheet 101 substantially perpendicular to the length of the motor vehicle in which a device 100 is to be used. In alternate embodiments, said second set of rigid arms 108 can be removably attached to said sheet 101 so that the sheet 101 can be laundered if needed. Said second set of rigid arms 108 can be spaced apart from each other in a manner that can allow for proper folding and storage of device 100 . A second set of rigid arms 108 can be plastic, fiberglass, metal, or any other known and/or convenient rigid material. [0032] A middle section 104 can also have a first adjustable headrest compartment 114 that can accommodate the height, width, and depth of the headrests of the driver and front passenger seats of a motor vehicle. Said first adjustable headrest compartment 114 can be comprised of at least one protrusion in a sheet 101 that can temporarily house the driver and front passenger seat headrests of a motor vehicle. Said first adjustable headrest compartment 114 can be at a location about a sheet 101 such that said at least one protrusion can easily fit over the driver and front passenger seat headrests, and said location can be customized for different motor vehicle types and models. [0033] A first adjustable headrest compartment 114 can have at least one fastening mechanism 112 located circumferentially about said first adjustable headrest compartment 114 . Said at least one fastening mechanism 112 can be utilized to fold the material of said first adjustable headrest compartment 114 over itself when the dimensions of the driver and front passenger seat headrests are smaller than the dimensions of said headrest compartment 114 in a fully unfolded position. Said at least one fastening mechanism 112 can be hook and loop, snaps, protrusion and aperture, or any other known and/or convenient fastening mechanism. A first adjustable headrest compartment 114 can also have at least one rigid arm 115 that can be permanently or removably attached to said first adjustable headrest compartment 114 and can be placed substantially perpendicular to the length of the motor vehicle in which a device 100 is to be used. In the embodiment shown in FIG. 1 , said at least one rigid arm 115 can be used primarily to assist in proper folding and storage of a device 100 , however in other embodiments said at least one rigid arm 115 can be used as a support means for a first adjustable headrest compartment 114 . Said at least one rigid arm 115 can be plastic, fiberglass, metal, or any other known and/or convenient rigid material. [0034] A rear section 106 can have a third set of rigid arms 108 that can be permanently attached to said sheet 101 substantially perpendicular to the length of the motor vehicle in which a device 100 is to be used. In alternate embodiments, said third set of rigid arms 108 can be removably attached to said sheet 101 so that the sheet 101 can be laundered if needed. Said third set of rigid arms 108 can be spaced apart from each other in a manner that can allow for proper folding and storage of device 100 . A third set of rigid arms 108 can be plastic, fiberglass, metal, or any other known and/or convenient rigid material. A rear section 106 can also have a second adjustable headrest compartment 116 that can accommodate the height, width, and depth of the headrests of the rear passenger seats of a motor vehicle. A second adjustable headrest compartment 116 can be have at least one section that can be comprised of a plurality of slits in a sheet 101 . The cut edges of each of said at least one section can be coupled with flexible material such that said at least one section of a compartment 116 can adjust to the dimensions of at least one rear passenger headrest while keeping said headrest covered. In the embodiment shown in FIG. 1 , a second adjustable headrest compartment 116 can have two sections for accommodating rear passenger headrests individually. In other embodiments, a second adjustable headrest compartment 116 can have just one section that can cover all read headrests. In yet another embodiment, a second adjustable headrest compartment 116 can have any number of sections for properly accommodating the rear headrests of a motor vehicle. In the embodiment shown in FIG. 2 , the outer surface of each section of a second adjustable headrest compartment 116 can be facing the rear windshield of a vehicle when in use, thereby deflecting the sun's rays back through said rear windshield. Said second adjustable headrest compartment 116 can be at a location about a sheet 101 such that it can easily fit over the rear passenger seat headrests, and said location can be customized to fit the dimensions of different motor vehicle types and models. [0035] A device 100 can have at least one removable stabilizing arm 120 . A removable stabilizing arm 120 can be rigid and can be made of metal, plastic, fiberglass, or any other known and/or convenient material. At least one end of said stabilizing arm 120 can have an aperture that can removably attach to a fastening device 42 , as shown in FIGS. 4-6 . In the embodiment shown in FIG. 4 , said stabilizing arm 120 has a square end with a square aperture there through, however in other embodiments the end of said stabilizing arm 120 can have any other known and/or convenient geometry. In FIG. 5 , said fastening device 42 is a rigid hook, but in other embodiments can be any other known and/or convenient fastening device complementary to said stabilizing arm 120 . As shown in FIG. 6 , said stabilizing arm 120 can pass over said fastening device 42 until it can lock into place temporarily. At least one fastening component 118 can be located on at least one side of a first adjustable headrest compartment 114 . A fastening component 118 can be adapted to accept one end of a stabilizing arm 120 . The use of a stabilizing arm 120 can force the front section 102 of a sheet 101 into a taut state, thereby properly positioning and securing said sheet 101 when in use. In use, the stabilizing arm 120 can be used to push the front end of a sheet 101 to the desired location on top of a vehicle's dashboard. Then to keep the sheet 101 in an extended position, the opposite end of a stabilizing arm 120 can be inserted inside a fastening compartment 118 . Similarly, and as shown in FIGS. 1 and 2 , a second stabilizing arm 120 can be used to force the rear section 106 of a sheet 101 into a taut state by first temporarily coupling one end of a stabilizing arm 120 with a fastening device 42 , and subsequently coupling the opposite end of a stabilizing arm 120 with a fastening compartment 118 . [0036] As shown in FIG. 3 , a middle section 104 of a sheet 101 can be removable from a device 100 . A sheet 101 can be physically separated into a front section 102 , a middle section 104 , and a rear section 106 . The edges of a middle section 104 can have a first set of fastening components 23 capable of complementarily fastening to a second set of fastening components 25 located on each of the back end of a front section 102 and the front end of a rear section 106 . In use, a user can first place a middle section 104 , including a first adjustable headrest compartment 114 , over the driver and front passenger seat headrests of a vehicle. Then, a user can removably fasten a front section 102 and a rear section 106 of a sheet to a middle section 104 using a first set of fastening components 23 and a second set of fastening components 25 . [0037] Despite the presence of rigid arms 108 and stabilizing arms 120 , the sides of a sheet 101 may sag slightly when in use. Thus, as shown in FIG. 7 , one embodiment of a device 100 can include at least one stretchable cord 50 located on a surface of a sheet 101 . In the embodiment in FIG. 7 , two stretchable cords 50 are shown, one being located on the front section 102 and another on the rear section 106 . Said stretchable cords 50 can be connected to a plurality of rigid arms 108 such that when a device 100 is in use, said stretchable cords 50 can assist in pulling the edges of said device 100 taut. A stretchable cord 50 can be made of rubber, polymer, or any other known and/or convenient elastomeric material. [0038] FIG. 8 depicts one embodiment of a device 100 in a semi-folded position. When a user desires to fold and store a device 100 , the first step is to remove the at least one stabilizing arm 120 from said device 100 . Then, a plurality of rigid arms 108 can be brought together in an accordion-like manner in order to fold said device 100 as compactly as possible. A set of straps 48 can be used to secure said device 100 in a folded position. As shown in FIG. 8 , straps 48 can be located on the underside of a middle section 104 . In other embodiments, straps 48 can be located at any other convenient location. Straps 48 can be tied around a device 100 , or can have other means of securing a device 100 in a folded position, such as by use of snaps or hook and loop. Once folded, a device 100 and stabilizing arms 120 can be stored in a trunk of a vehicle, or at any other desired location. [0039] Another method of folding a device 100 is depicted in FIG. 9 . A plurality of loops 54 can be attached to a plurality of rigid arms 108 . Said loops 54 can be made of plastic, string, or any other known and/or convenient material. Said at least one stabilizing arm 120 can be threaded through one or more of a plurality of loops 54 . The loops 54 which are closest to the front and rear ends of a sheet 101 can have extensions 200 that can be anchored at a middle section 104 . As shown in FIGS. 10-12 , at least one stabilizing arm 120 can have a forked end that can removably engage at least one fastening device 42 located at the front and/or rear ends of a device 100 . Said fastening device 42 can have an aperture for accepting said forked end of said stabilizing arm 120 . In order to fold a device 100 , a user can pull extensions 200 towards the middle section 104 and away from the front and rear ends of a device 100 . This action can force stabilizing arms 120 towards said middle section 104 , thereby disengaging them from said fastening device 42 . By continuing to pull extensions 200 , a user can efficiently fold a device 100 . [0040] As shown in FIG. 13 , a plurality of rigid arms 108 can be bent or curved such that the front section 102 and rear section 106 of a sheet 101 are sloped and can reflect sunlight out the side windows of a vehicle when in use. FIG. 14 shows a side view of this embodiment. FIG. 15 shows a side view of another embodiment in which a plurality of rigid arms 108 can be bent or curved to create the aforementioned slope effect, but the outermost rigid arms 108 can be bent or curved to a lesser degree than the innermost rigid arms 108 such that a sloping effect is created along the length of a device 100 from the middle section 104 outwards to either end of a sheet 101 . [0041] As shown in FIGS. 16 and 17 , a sheet 101 can be made of rigid or semi-rigid material. In this embodiment, a plurality of rigid arms 108 can be omitted. Instead, a plurality of creases 58 can extend across the width of a sheet 101 , perpendicular to the length of a vehicle in which the device 100 is to be used. Said creases 58 can provide support and folding means for said device 100 . A plurality of loops 54 as described above can be used in this embodiment, however said loops would be attached directly to a sheet 101 instead of a plurality of rigid arms 108 . A sloping effect similar to that shown in FIGS. 13-15 can still be achieved when a sheet 101 is made of rigid material. As shown in FIG. 18 , in the absence of a plurality of rigid arms 108 , a plurality of diamond-shaped sections 60 can be located along the longitudinal midline of a sheet 101 . Said diamond-shaped sections 60 can be made of flexible material attached to said sheet 101 . The material on either side of said diamond-shaped sections 60 can be angled downward, thereby deflecting the sun's rays out of the side windows of a vehicle. During the folding process of a device 100 , said diamond-shaped sections 60 can fold inward to allow for compact folding of a device 100 . FIG. 19 depicts a fully folded back view of this embodiment, wherein the diamond-shaped sections 60 are gathered inside a pyramid-shaped space that is formed when a device 100 is full folded. [0042] As shown in FIG. 20 , a plurality of rigid arms 108 can be incorporated into a device 100 where a sheet 101 is made of rigid material, even if diamond-shaped sections 60 are also incorporated. Incorporation of said plurality of rigid arms 108 can be for added support of the overall structure of a device 100 . In the embodiment in FIG. 20 , said rigid arms 108 are shorter than in previous embodiments. [0043] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the invention as described and hereinafter claimed is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
A motor vehicle accessory capable of shielding the interior of a car from the sun, specifically a device that can cover the entire interior surface of a vehicle.
1
CROSS-REFERENCE TO RELATED APPLICATION [0001] The present application derives priority from U.S. Provisional Application Ser. No. 61/888,261 filed Oct. 8, 2013. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to heat activated transfers and appliques and, particularly, to a light-weight breathable heat-transfer comprised of numbers, letters, logos, graphics, and other indicia which do not change the physical and visual characteristics of performance fabrics to which they are applied, including breathability, moisture-wicking characteristics, stretch and recovery, and launderability. [0004] 2. Description of the Background [0005] Manufacturers of performance apparel, uniforms, swimwear, and sports accessories use various methods to apply a variety of indicia, such as text, numbers, logos, graphics, and other indicia, to garments and textiles for decoration and identification, among other things. Common application technologies include silk-screening, screen-printing, sonic welding, direct embroidery, and heat activated transfers. [0006] Silk-screening of logos or emblems is commonly used, but this process does not result in a product that withstands repeated stretching, and is complex and time-consuming. In addition, the designs created by silk-screening are flat, lack texture, and do not withstand repeated stretching or industrial or home washings. Consequently, many companies prefer embroidery as their primary method for applying decoration and identification. [0007] Sonic welding is another method used to apply decoration and identification to garments and textiles. The nature of a sonic-welded bond is a fusing of materials which results in a rigid material interface. The rigid interface causes cracking and potential sheering when stretched, and can debond after repeated home and industrial laundering. Sonic welding allows texturing, but also requires chemical compounds that some companies find unacceptable. Moreover, sonic welding requires the creation of unique, expensive special dies for any design to be applied. Consequently the process is slow, relatively expensive, and not well-suited for the performance apparel industry and its small-batch production/quick-changeover requirements. Indeed, this process typically is not used by the uniform industry for these reasons. Embroidery has instead become the primary method for applying decoration and identification. [0008] Embroidery is typically performed by a machine that applies stitching of various colors and styles to fabric to create a design. Embroidered designs have a much greater aesthetic value, and stand repeated home and industrial launderings. Yet this too is a complex, time-consuming process. While appliques stitched have more potential to stretch mechanically then welded bonds they are still limited by the sewn threads which constrain elongation and can break if stretched. [0009] Thermally activated adhesive coatings are also used to apply appliques to garments and textiles. One common type of applique, typical of sports jersey and uniform, numbering and lettering, is a layered applique comprising a solid first base layer that defines a numeral or letter and one or more top layers that are the same shape, but smaller than the layer below it, thereby creating a three dimensional appearance. Typically, each additional top layer is stitched to the layer below it. On the back of the solid base layer is a layer of thermally activated adhesive that covers the entire back surface. The solid fabric layers in combination with the solid adhesive coating result in a rigid, thick and relatively heavy, and moisture/air impermeable applique. Thus, when such an applique is applied to a substrate that is more flexible, lighter, or more breathable than the applique itself, the substrate's characteristics are lost. [0010] The destruction or interference with the characteristics of the underlying fabric is a significant disadvantage, especially in the context of performance apparel with moisture-wicking and/or breathability characteristics, because the applique undermines the garment's comfort and performance. In addition to unfavorably changing the physical characteristics of the substrate, these appliques also change the substrate's visual characteristics, such as the amount of drape. Another problem to overcome particularly in contact sports such as football and hockey is the potential for the garment and appliques to be pulled causing a sheer which can break the bond between garment and applique whether sewn or adhered with an adhesive. [0011] It would be greatly advantageous to provide a heat sealed applique that can be applied to any garment or textile without obstructing any performance characteristics of the garment or textile, and which is therefore particularly well-suited for lightweight, breathable and/or moisture-wicking textiles commonly used in performance sports apparel. SUMMARY OF THE INVENTION [0012] It is, therefore, an object of the present invention to provide a heat sealed applique forming indicia such as text, numbers, logos, graphics, and other indicia that does not change the physical characteristics, such as stiffness, pliability, breathability, stretch and recovery, moisture-wicking properties, weight, or launderability of a performance fabric substrate to which the applique is applied. [0013] It is another object of the present invention to provide a heat sealed applique that does not change the visual characteristics, such as drape, of the substrate to which the applique is applied. [0014] It is yet another object of the present invention to provide a heat sealed applique that resembles a traditional, layered applique often used for lettering and numbering on sports jerseys and uniforms. [0015] And it is another object of the present invention to provide a heat sealed applique that can be manufactured cost effectively. [0016] According to the present invention, the above-described and other objects are accomplished, by an applique comprising an outer perimeter fabric frame of a particular weave, fiber composition and cut pattern, the fabric frame having a thermally activated adhesive coating on one side. The fabric frame is cut (for example, die-cut, laser-cut, rotary-blade-cut, water-jet cut or otherwise cut) from a blank in the form of an outline of a discrete predetermined indicia (text, number, logo, graphic, etc.). The cut pattern comprises an inner cut and conforming outer cut of slightly expanded dimension that results in a substantially contiguous border framing the desired indicia. A central fabric panel formed of mesh or other perforated or highly porous material is cut with a single cut conforming to those of the fabric frame, but of dimensions intermediate to those of the inner cut and conforming outer cut of the fabric frame. Dimensions are structurally important, especially the following dimensional parameters for the central fabric panel relative to the fabric frame: 1) the inner and outer cut of the fabric frame are identical but scaled; 2) the width of the inner cut of the fabric frame is at all points constrained to be smaller than the width of the central, fabric panel (measured in the same direction); and 3) the difference between the outer cut and inner cut of ore fabric frame (e.g., the width of the border or margin) is constrained to a maximum percentage of the total width of the applique (measured in the same direction). The fabric frame is adhered by a particular thermally activated adhesive coating to an underlying performance fabric substrate, effectively sandwiching the central fabric panel (substantially unadhered) there between and overtop the substrate. The adhesive flows through the mesh of the central panel bonding both layers, and yet the bonded applique does not substantially affect the flexibility, breathability, and weight of the underlying substrate because it is only around the narrow outer perimeter of the applique. Moreover, both the fabric frame and its thermally activated adhesive coating have the ability with the particular adhesive type (described below) to stretch and recover as the garment is pulled, which prevents the adhesive bond from sheering (a common cause of numbers or characters detaching from the garment). The resulting applique forms a robust and launderable bond, but does not substantially change the physical and visual characteristics of the substrate to which the applique is applied. Moreover, since the outer periphery of the fabric frame is slightly larger than the central fabric panel, the frame remains visible. A layered embroidery appearance can be created by contrast coloring the fabric frame versus central fabric panel, and this is further enhanced by printing multiple color graphics along the periphery of the fabric frame. [0017] The following is a non-limiting example of a suitable process for manufacturing the applique described above. The applique can be manufactured by applying a thermally activated adhesive layer to one side of a first fabric blank. The coated first fabric blank is kiss cut to form a predetermined indicia pattern that is preferably a discrete letter, number, logo or other indicia. In addition to the indicia pattern, a conforming outline cut of slightly larger dimension is made through, me coated perimeter textile and the carrier sheet. The inner excess perimeter textile is removed to form an opening in the shape of the indicia pattern. [0018] A central fabric panel formed of mesh or other perforated or highly porous center textile, a separate textile, is cut in conformance with the opening in the fabric frame, but using a dimension which will be wider than the inner cut used for the fabric frame. The cut central fabric panel is inlayed within the opening in the perimeter frame, against the thermal adhesive layer, very slightly overlapping the interior cut of the fabric frame. The perimeter frame is bonded to the performance fabric, sandwiching the central panel there between, and the two are bonded thereto by heat pressing, on top and bottom, which partially melts the adhesive coating on the perimeter frame through the mesh central panel and to the substrate. [0019] To apply the applique, the backing material underneath is removed, and the applique is placed on the garment and heat pressed to activate the adhesive coating. Using this process, the applique only has an adhesive layer around its outer perimeter, leaving the center portion mostly uncoated. BRIEF DESCRIPTION OF THE DRAWINGS [0020] Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of me preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which: [0021] FIG. 1 is a front view of a heat-activated applique 2 according to an embodiment of the present invention. [0022] FIG. 2 is a front composite view of the heat-activated applique 2 as in FIG. 1 . [0023] FIG. 3 is a side view of the heat-activated applique 2 as in FIG. 1 . [0024] FIG. 4 is a flow chart illustrating the construction steps for manufacture of the heat-activated applique 2 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0025] The present invention is a light-weight breathable heat-transfer comprised of individual numbers, letters, logos, graphics, and other indicia. The transfer will not change or impede the physical characteristics of performance fabrics to which they are applied, including breathability, moisture-wicking characteristics, stretch and recovery, and launderability. [0026] FIG. 1 is a front view of a heat-activated applique 2 according to an embodiment of the present invention. The applique 1 portrays a preselected numeric indicia (here a “5” in wide block script). FIG. 2 is a front composite view of the heat-activated applique 2 of FIG. 1 and FIG. 3 is a side view. [0027] The applique 2 comprises a fabric frame 10 that is cut (die-cut, laser-cut, rotary-blade-cut, water-jet cut or otherwise suitably cut) from a first textile blank in the form of an outline of the predetermined indicia. The indicia may be any discrete text, number, logo, graphic, etc, hi general, the first blank is a knitted/woven stretchable fabric blank comprising a material having a yam strands made of synthetic fibers, and a second elastomeric yam strand. The first yarn strands are knitted/woven together with the elastomeric second strand to create a single blank of woven/knitted fabric. The knitted/woven blank has a specific fiber content and combination of the two strands, of yarn. The first yarn strands are preferably 100% polyester, which is the dominate fiber of the fabric blank. This is important because polyester can be colored utilizing dye sublimation printing processes which are superior in surviving deformations. Deformation of other synthetics less amenable to dye sublimation can result in sheering of color pigment from the printed product. As an alternative to polyester, the first yam strands may comprise nylon inasmuch as it can be digitally printed utilizing acid dyes. [0028] The elastomeric yam strand of the knitted/woven stretchable fabric blank may be comprised of any elastic textile fiber, however, it is preferred that this material be made of the elastomeric textile fiber known as spandex. Therefore, in the preferred embodiment, the knitted/woven fabric blank comprises a blend of polyester or poly-cotton yam and spandex, wherein the spandex fiber content is constrained to within an acceptable range of from 3 to 15%, and most preferably is 6%. This may be achieved with a knit/weave ratio of synthetic yarn/spandex yarn of from 33:1 to 20:1, and identical deniers. One skilled in the art will understand that the variation between fabric blends may also be made possible by varying the ratio of yams and the structure of the knit or weave pattern. [0029] The fabric frame 10 is cut (die, laser, rotary-blade, water-jet, etc.) from the finished textile blank using an inner cut and conforming outer cut of slightly expanded dimensions, that results in a substantially contiguous border framing the desired indicia. Preferably, the fabric frame 10 provides a border-width or margin within a range of from 4-8 mm across, and most preferably a 5-6 mm margin. [0030] The fabric frame 10 is coated with a polyurethane adhesive on one side having a modulus of between 3 to 10 Newtons and a thickness of between 50 um (microns) or 0.002 inches, and 175 um or 0.007 inches. A suitable adhesive is Bemis Sewfree™ 3405 applied in a single layer 50-175 um coating applied uniformly to the perimeter. This ensures sufficient adhesive to secure the frame 10 and mesh central panel 20 together around their perimeter and to bond to the garment as well. [0031] A central fabric panel 20 is formed from a second blank of suitable mesh or other perforated or highly porous material, most preferably a polyester or nylon mesh fabric blank. The central fabric panel 20 is cut (die, laser, rotary-blade, water-jet, etc.) from the mesh fabric blank with a single cut generally conforming to those of the fabric frame 10 , but of dimensions intermediate to those of the inner cut and conforming outer cut of the fabric frame 10 . Preferably, the central fabric panel 20 is cut to shape to provide a margin of overlap when superposed on fabric frame 10 within a range of from 2-4 mm across, and most preferably a 3 mm overlap margin. [0032] Dimensions are structurally important to the present invention, and in particular there are dimensional parameters for the central fabric panel 20 relative to the fabric frame 10 (or vice versa). The parameters are as follows: 1) the inner and outer cut of the fabric frame 10 are substantially identical but scaled; 2) the width of the inner cut of the fabric frame 10 is at all points smaller than the width of the central fabric panel 20 (measured at the same point and in the same direction) by a differential of within a range of from 2-4 mm: and 3) the difference between the outer cut and inner cut of the fabric frame 10 (e.g., the width of the border) is constrained to no more than forty-five, percent of the total width of the applique (measured at the same point and in the same direction). [0033] A lower laminating layer 30 underlies the fabric frame 10 for laminating the applique 2 to a performance fabric substrate or product. Laminating layer 30 comprises a compatible heat activated adhesive layer. Suitable thermoplastic adhesives for the present invention include methane adhesives such as Bemis Sewfree 3206D urethane films produced by Bemis Associates Inc. or similar urethane films produced by Deerfield Urethanes Inc. Laminating layer 30 preferably has a hot melt point of from 175-300 degrees F. and most preferably between 250 T-280 T. [0034] The central fabric panel 20 is registered to and attached beneath the fabric frame 10 facing the adhesive-coated side, and is adhered thereby to the underlying performance fabric substrate 30 in a sandwich configuration, the overlap margin allowing for a good bond between all three layers 10 , 20 , 30 . Upon melting the laminating layer 30 flows through the mesh of the central fabric portion 30 and bonds to the underlying substrate, adhering all three layers 10 , 20 , 30 . The foregoing attachment method provides a stretch and recovery characteristic that would not be otherwise possible, for example, by a sewn perimeter which would mechanically limit stretch and recovery at the seam. [0035] The bonded laminating layer 30 does not substantially affect the flexibility, breathability, and weight of the applique 2 or the underlying substrate because it is only around the narrow outer perimeter of the applique on fabric frame 10 . Moreover, both the fabric frame 10 and its thermally activated polyurethane adhesive coating have the ability to stretch and recover as the garment is pulled, which prevents the adhesive bond from sheering (a common cause of numbers or characters detaching from the garment). The resulting applique 2 provides a robust and launderable aesthetic, but does not substantially change the physical and visual characteristics of [0036] the substrate to which the applique 2 is applied. Moreover, since the outer periphery of the fabric frame 10 is slightly larger than the central fabric panel, both frame 10 and dye-sublimated borderline (blue) remain visible. [0037] The color of the fabric frame 10 is preferably chosen with regard to the color of the central fabric panel 20 to contrast or accentuate those color(s), thereby providing an aesthetically pleasing color contrast and embroidered appearance. Preferably, a 3 mm margin at the edge of the central fabric panel 20 and extending onto the fabric frame 10 is printed using dye sublimation in a third color (blue is shown) to add further color contrast and accentuate the embroidered appearance. [0038] FIG. 3 is a flow chart illustrating an exemplary sequence of construction steps for manufacture of the heat-activated applique 2 . One skilled in the art will understand that there are suitable variations and alternatives to the above-described production process and the following is meant to serve as but one non-limiting example. [0039] As seen in step 100 , beginning with the knitted/woven fabric blank, the entire blank is coated with the polyurethane adhesive, e.g., Bemis Sewfree™ 3206D adhesive. [0040] At step 200 , the fabric blank is cut in the form of an outline of the predetermined indicia, defining fabric frame 10 . One method to do this employs a digitally-controlled laser cutting system in which variable-intensify laser beam capable of high speed movement. The cutting and engraving station includes a cutting bed upon which the fabric blank is placed and having an X-Y plotter with articulating laser head thereon or a rastering laser that directs the laser beam by driving mirrors to direct the beam on the bed. The heat from the laser beam cuts selectively in a first pass to create the inner cut, and then in a second pass to create the conforming outer cut of slightly expanded dimensions. [0041] Upon completion of cutting step 200 , the laser head returns to a point of origin, allowing the user to retrieve the applique 2 . The waste portions are removed to yield a substantially contiguous fabric frame 10 having a margin within a range of from 4-8 mm across, and most preferably a 5-6 mm margin. [0042] At step 300 , the second blank of mesh is cut (as described above) with a single cut conforming to those of the fabric frame 10 to form central fabric panel 20 with dimensions intermediate to those of the inner cut and conforming outer cut of the fabric frame 10 , leaving a 2-3 cm margin of overlap as described above. [0043] At step 400 , the bonded laminating layer 30 is laminated to the fabric frame 10 . [0044] At step 500 , central fabric panel 20 is sandwiched between the fabric frame 10 and underlying performance substrate, centrally, with the requisite 2-3 cm margin of overlap within frame 10 . Lamination is effected. This melts the thermal adhesive layer 30 through the mesh panel 20 to the underlying performance fabric substrate; Flatbed laminating is preferred, and a suitable laminating machine is the Glenro HTH or HTM model flatbed laminator from Glenro Inc., 39 McBride Ave., Paterson, N.J. 07501-1799. These are PLC-controlled machines and the heat is set in accordance with the hot melt point range of heat sensitive polyurethane adhesive, for example, 307 degrees F. Lamination of a pressure sensitive adhesive can alternatively be used with application occurring by the use of pressure rolls or platens. [0045] At step 600 , the border of the central fabric panel 20 and fabric frame 10 is printed with a 2 cm contrast color using dye sublimation printing. [0046] The applique 2 may be thermally applied to a product in a conventional manner. Electrically heated platen presses are the most commonly used means of applying the adhesive coated appliques 1 to garments or other articles. Temperature, pressure, and dwell time are the three basic seal conditions that must be controlled in order to ensure a proper bond. These three parameters should be established for each specific garment and embroidery combination. Generally, for the preferred embodiment illustrated above the temperature is held at approximately 250 degrees F (glueline temperature at which laminating layer 30 will melt), and this is sustained for 5-10 seconds once the temperature has been reached. Very thick materials will usually require a longer dwell time, to allow the greater mass to be heated, and to conduct the heat to the glue line. If pressure sensitive adhesives are utilized application can be accomplished by applying uniform pressure to the applique to adhere it to the garment. Adhesive activation can also be achieved through home ironing with a low melt activation film. [0047] It should now be apparent that the foregoing results in a color-printed and/highlighted applique 2 as in FIG. 1 that gives an aesthetically-pleasing embossed or otherwise color-contrasted appearance in a form that is easily applied to a garment or other textile. Moreover, all of the printing and cutting may be controlled by common digital files, greatly increasing efficiency. This has been a description of the present invention and, the preferred embodiment of the present invention, as well as various alternate embodiments of the present invention.
An applique comprising an outer perimeter fabric frame of a particular weave, fiber composition and cut coated with a laminating adhesive, and inlayed wife a central fabric panel formed of mesh or other perforated or highly porous material. Lamination causes the adhesive to melt through the mesh central panel and bond the two layers to an underlying performance fabric substrate. The resulting applique forms a robust and launderable bond, but does not substantially change fee physical and visual characteristics of a performance fabric substrate to which the applique is applied. Moreover, a layered embroidery appearance can be created by contrast coloring the fabric frame versus central fabric panel, and this is further enhanced by printing a multi-color graphic along the periphery of the fabric frame.
3
FIELD OF THE INVENTION The present invention relates to a tubular stent/graft apparatus. More particularly, the present invention relates to a composite intraluminal device including a helically formed tubular stent/graft assembly formed from a planar pre-assembly having a wire stent material laminated between ePTFE strips. BACKGROUND OF THE INVENTION An intraluminal prosthesis is a medical device commonly known to be used in the treatment of diseased blood vessels. An intraluminal prosthesis is typically used to repair, replace, or otherwise correct a damaged blood vessel. An artery or vein may be diseased in a variety of different ways. The prosthesis may therefore be used to prevent or treat a wide variety of defects such as stenosis of the vessel, thrombosis, occlusion, or an aneurysm. One type of endoluminal prosthesis used in the repair of diseases in various body vessels is a stent. A stent is a generally longitudinal tubular device formed of biocompatible material which is useful to open and support various lumens in the body. For example, stents may used in the vascular system, urogenital tract and bile duct, as well as in a variety of other applications in the body. Endovascular stents have become widely used for the treatment of stenosis, strictures, and aneurysms in various blood vessels. These devices are implanted within the vessel to open and/or reinforce collapsing or partially occluded sections of the vessel. Stents are generally open ended and are radially expandable between a generally unexpended insertion diameter and an expanded implantation diameter which is greater than the unexpended insertion diameter. Stents are often flexible in configuration, which allows them to be inserted through and conform to tortuous pathways in the blood vessel. The stent is generally inserted in a radially compressed state and expanded either through a self-expanding mechanism, or through the use of balloon catheters. A graft is another type of commonly known type of intraluminal prosthesis which is used to repair and replace various body vessels. A graft provides an artificial lumen through which blood may flow. Grafts are tubular devices which may be formed of a variety of material, including textiles, and non-textile materials. One type of non-textile material particularly useful as an implantable intraluminal prosthesis is polytetrafluoroethylene (PTFE). PTFE exhibits superior biocompatability and low thrombogenicity, which makes it particularly useful as vascular graft material in the repair or replacement of blood vessels. In vascular applications, the grafts are manufactured from expanded polytetrafluoroethylene (ePTFE) tubes. Such tubular grafts may be formed from extruded tubes, sheets or films. These tubes have a microporous structure which allows natural tissue ingrowth and cell endothelization once implanted in the vascular system. This contributes to long term healing and patency of the graft. Grafts formed of ePTFE have a fibrous state which is defined by interspaced nodes interconnected by elongated fibrils. The spaces between the node surfaces that is spanned by the fibrils is defined as the internodal distance (IND). Porosity of a graft is measured generally by IND. In order of proper tissue ingrowth and cell endothelization, grafts must have sufficient porosity obtained through expansion. When the term expanded is used to describe PTFE, it is intended to describe PTFE which has been stretched, in accordance with techniques which increase IND and concomitantly porosity. The stretching may be in uni-axially, bi-axially, or multi-axially. The nodes are spaced apart by the stretched fibrils in the direction of the expansion. Properties such as tensile strength, tear strength and radial (hoop) strength are all dependent on the expansion process. Expanding the film by stretching it in two directions that are substantially perpendicular to each other, for example longitudinally and transversely, creates a biaxially oriented material. Films having multi-axially-oriented fibrils may also be made by expanding the film in more than two directions. Porous ePTFE grafts have their greatest strength in directions parallel to the orientation of their fibrils. With the increased strength, however, often comes reduced flexibility. While ePTFE has been described above as having desirable biocompatability qualities, tubes comprised of ePTFE, as well as films made into tubes, tend to exhibit axial stiffness, and minimal radial compliance. Longitudinal compliance is of particular importance to intraluminal prosthesis as the device must be delivered through tortuous pathways of a blood vessel to the implantation site where it is expanded. A reduction in axial and radial flexibility makes intraluminal delivery more difficult. Composite intraluminal prosthesis are known in the art. In particular, it is known to combine a stent and a graft to form a composite medical device. Such composite medical devices provide additional support for blood flow through weakened sections of a blood vessel. In endovascular applications the use of a composite graft or a stent/graft combination is becoming increasingly important because the combination not only effectively allows the passage of blood therethrough, but also ensures patency of the implant. However, in each of the above described sheet or film cases, the stent and the graft are separately formed and then attached. This manner of construction results in potential separation of the graft from the stent because it is difficult to affix tubular structures to one and another. The present invention seeks to provide a more efficient and predictable means of forming a stent/graft assembly by forming the tubular covering and tubular stent simultaneously. SUMMARY OF THE INVENTION It is an object of the present invention to provide an improved composite stent/graft apparatus. It is a further object of the present invention to provide tubular stent/graft devices that can be manufactured by continuous techniques. It is a further object of the present invention to produce the assembly strips in a continuous manufacturing technique to reduce the cost of manufacturing the tubular stent/grafts. It is still a further object of the present invention to provide a tubular stent/graft that has consistent wall properties without undesired seams, bumps or weak points. In the efficient attainment of these and other objects, the present invention provides a tubular stent/graft apparatus comprising a planar graft material having a planar stent wire attached to one of its sides to form a strip assembly. The strip assembly is helically wound to form a tubular stent/graft structure. The stent may be radially expandable, and the stent may be chosen from a wide variety of stent materials and configurations. For example, the stent may be self-expandable, balloon expandable or made from a memory alloy, the configuration of which can be controlled by temperature. The present invention further relates to a method of making a tubular stent/graft assembly comprising the steps of (i) forming a substantially planar strip and wire assembly comprising planar graft material formable into a graft and planar stent wire formable into a radially adjustable stent, wherein the wire is attached lengthwise along the length of said planar strip; and (ii) helically winding the substantially planar strip and wire assembly to form said tubular stent graft assembly. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective showing of one embodiment of an assembly strip of the present invention including a planar graft strip and a planar undulating wire for forming a tubular stent/graft structure for use as an intraluminal device. FIG. 2 is a cross-sectional view of the assembly strip of FIG. 1 taken along line 2 — 2 . FIG. 3 is a perspective of a portion of a continuous tubular stent/graft structure formed by helically winding the assembly strip of FIG. 1 . FIG. 4 is a cross-sectional view of a portion of the tubular stent/graft structure of FIG. 3 taken along line 4 — 4 . FIG. 5 is a perspective of a further embodiment of an assembly strip of the present invention containing two planar graft strips on the top and bottom surfaces of an undulating wire for forming a tubular stent/graft structure for use as an intraluminal device. FIG. 6 is a cross-sectional view of the assembly strip of FIG. 5 taken along line 6 — 6 . FIG. 7 is a perspective of a portion of a continuous tubular stent/graft structure formed by helically winding the assembly strip of FIG. 5 . FIG. 8 is a cross-sectional view of a portion of the continuous tubular stent/graft structure of FIG. 7 taken along line 8 — 8 . FIG. 9 illustrates a method for helically winding an assembly strip on mandrel to form a tubular stent/graft structure. FIG. 10 is a perspective showing of a further embodiment of an assembly strip of the present invention containing a graft strip and a straight wire for forming a tubular stent/graft structure for use as an intraluminal device. FIG. 11 is a cross-sectional view of the assembly strip of FIG. 10 taken along line 11 — 11 . FIG. 12 is a perspective of a portion of a continuous tubular stent/graft structure formed by helically winding the assembly strip of FIG. 10 . FIG. 13 is a cross-sectional view of a portion of the continuous tubular stent/graft structure of FIG. 12 taken along line 13 — 13 . FIG. 14 is a perspective of a portion of a tubular stent/graft structure formed by helically winding the assembly strip of FIG. 10 without overlapping adjacent graft strip portions. FIG. 15 is a cross-sectional view of a portion of the tubular stent/graft structure of FIG. 14 taken along line 15 — 15 . FIG. 16 is perspective showing of a further embodiment of an assembly strip of the present invention having a planar graft strip and a planar ribbon stent strip for forming a tubular stent/graft structure. FIG. 17 is a cross-sectional view of the assembly strip of FIG. 16 taken along line 17 — 17 . FIG. 18 is an illustration of a portion of a tubular stent/graft structure formed by helically winding the assembly strip of FIG. 16 without overlapping adjacent graft strip portions. FIG. 19 is perspective showing of yet a further embodiment of an assembly strip of the present invention for forming a tubular stent/graft structure having non-overlapping adjacent graft strip portions. FIG. 20 is a cross-sectional view of the assembly strip of FIG. 19 taken along line 20 — 20 . FIG. 21 is an illustration of a portion of a tubular stent/graft structure formed by helically winding the assembly strip of FIG. 19 without overlapping adjacent graft strip portions. FIG. 22 illustrates a method for helically winding about a mandrel an assembly strip having a stent wire protruding beyond a graft strip for forming a tubular stent/graft structure. FIG. 23 is a perspective showing of an additional embodiment of an assembly strip of the present invention having a planar graft strip and an overlapping planar ribbon stent strip for forming a continuous tubular stent/graft structure. FIG. 24 is a cross-sectional view of the assembly strip of FIG. 23 taken along 24 — 24 . FIG. 25 is an illustration of a portion of a continuous tubular stent/graft structure formed by helically winding the assembly strip of FIG. 23 . FIG. 26 is a cross-sectional view of a portion of the continuous tubular stent/graft structure of FIG. 25 taken along line 26 — 26 . FIG. 27 is an exploded perspective view of an assembly strip of the present invention having a planar graft strip and a cuffed planar ribbon stent strip for forming a continuous tubular stent/graft structure. FIG. 28 is a cross-sectional view of the assembly strip of FIG. 27 . FIG. 29 is an illustration of a portion of a continuous tubular stent/graft structure formed by helically winding the assembly strip of FIG. 27 . FIG. 30 is a cross-sectional view of a portion of the continuous tubular stent/graft structure of FIG. 29 taken along line 30 — 30 . FIG. 31 is a perspective showing, partially in section, of an assembly strip having a planar graft strip and a planar ribbon stent strip with a longitudinal fold for forming a tubular stent/graft structure. FIG. 32 is a perspective showing, partially in section, of a tubular stent/graft structure having a substantially continuous luminal surface formed by helically winding the assembly strip of FIG. 31 . FIG. 33 is a perspective showing, partially in section of an assembly strip having a planar graft strip and a planar ribbon stent strip with two longitudinal folds for forming a tubular stent/graft structure. FIG. 34 is an illustration of a portion of a tubular stent/graft structure having a substantially continuous exterior surface formed by helically winding the assembly strip of FIG. 33 . FIG. 35 is a cross-sectional view of a portion of the tubular stent/graft structure of FIG. 34 taken along line 35 — 35 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention provides a more efficient and predictable means, as compared to the prior art, of forming a stent/graft composite device where the grafts and the stent are simultaneously formed. A planar assembly strip, having planar graft material securely fixed to a planar wire used to form a tubular structure. Because the assembly strip contains a securely fixed graft and wire, the present invention avoids some of the sealing and integrity problems inherent in the prior art as the tubular intraluminal device is created. For example, attaching planar graft material to a planar wire is more predictable, as compared to techniques in the prior art, than attaching graft material to tubular stents or even attaching tubular coverings to tubular stents. Because such a planar assembly requires positioning of surfaces and edges in only two dimensions, such a two dimensional positioning is more easily accomplished, and thus more predictable, than a three dimensional positioning. Such three dimensional positioning of both a stent/graft material is required for the techniques disclosed in the prior art where tubular stents and tubular grafts are attached to one and the other. In some embodiments of the present invention, additional sealing of graft materials is not required after creating a tubular structure. In other embodiments, additional sealing of the graft material is required to form fluid tight conduits for use as intraluminal devices. Such additional sealing, however, is more predictable over the prior art because the assembly strip is formed into tubular shapes with well-defined seams of graft material that can be tightly sealed. FIGS. 1 and 2 depict a strip assembly 100 for forming a first embodiment of a tubular stent/graft apparatus of the present invention. Strip assembly 100 comprises of a planar graft strip 102 and a planar undulating wire 104 . Strip assembly 100 can be formed into a tubular structure by helically winding the strip assembly 100 on a mandrel. Planar wire 104 provides, among other things, support of the graft strip 102 for use as an intraluminal device. Assembly strips of the present invention can be produced by continuous manufacturing techniques. Long strips of the assembly strips can be cut to form the desired size of the stent/graft assembly. As used herein, the term “wire” shall refer to stent material of a slender shape with various defined cross-sections having a cross-sectional dimension substantially less than the length of the slender shape. Such cross-sections are not limited to spherical shapes, but other shapes, such as, but not limited to, rectangular, square and oval, may suitably be used. For example, the stent material can be in the shape of a rectangular strip. Furthermore, as used herein, the term “strip” shall refer to a long narrow piece of graft material of approximately uniform breadth. For example, graft strip 102 is described as a strip because a length between a first end 106 and a second end 108 is substantially greater in dimension than the length, or breadth, between a first edge 110 and a second edge 112 of planar side 114 . Also, as used herein, the term “planar” shall refer to a surface, edge or structure that can be substantially defined in two dimensions. For example, planar side 114 is described as planar because its surface is essentially flat, where it can be defined by vectors in two dimensions, not defined by a vector to any large extent a third dimension. Planar wire 104 is disposed in substantially abutting relationship to the surface of planar side 114 . Planar wire 104 may be fixed to the graft strip 102 by a variety of well-known techniques For example planar wire 104 may be fixed to the graft strip 102 by compressing the planar wire 104 thereon, by bonding the stent wire 104 thereon with adhesives or polymer solvents, followed by an application of heat, in well-known fashion. Heat may be applied to strip assembly 100 through external heating means (not shown), such as an oven. For example, a coating of fluorinated ethylene propylene (FEP) may be applied to the surface of planar side 114 , and planar wire 104 may be adhesively bonded thereon with the application of heat. Planar wire 104 is disposed onto planar side 114 in an undulated pattern. Preferably, the undulated pattern of planar wire 104 is a smooth and regular sinuous pattern, to provide, among other things, flexibility in the structure of the intraluminal device. A feature of such flexibility, imparted by an undulated planar stent wire, is that the tubular structure formed therefrom is radially adjustable. Such radial adjustability can be accomplished through use of either a self-expanding mechanism or through the use of balloon catheters, in well-known fashion. Furthermore, planar wire 104 is disposed so that it does not extend beyond edges 110 and 112 of planar side 114 . Planar wire 104 is so disposed thereon to allow portions of the graft strip 102 to contact one and another as assembly strip 100 is helically wound on a mandrel to form a tubular structure. FIGS. 3 and 4 depict the strip assembly 100 that has been helically wound. Assembly strip 100 is helically wound to form a substantially continuous tubular stent/graft structure 118 . A technique for helically winding a strip assembly is described below in conjunction with FIG. 10 . In a preferred embodiment, tubular stent/graft structure 118 has a generally spherical cross-section. Other cross-sectional shapes, such as, but not limited to, oval, may suitably be used. Planar side 116 forms an exterior surface 120 of the tubular stent/graft structure 118 . Planar side 114 and planar wire 104 form an interior or luminal surface 122 of the tubular stent/graft structure 118 . Strip assembly 100 is helically wound on a mandrel so that successive helical windings create overlaps of graft strip 102 . A portion of planar side 114 abuts a portion of planar side 116 on each successive helical winding, thereby creating an overlap. Such overlaps form a seam which can be sealed by aforementioned techniques. Upon sealing said seam, the tubular stent/graft structure 118 becomes a substantially fluid tight conduit. FIGS. 5 and 6 depict a second embodiment of an assembly strip 124 for use as an intraluminal device. Assembly strip 124 comprises planar wire 126 disposed between planar graft strips 128 and 130 . Planar graft strips 128 and 130 are composed of the same material as graft material 102 . Planar wire 126 undulates between planar graft strips 128 and 130 along the length of said strips therebetween. Planar wire 126 is essentially planar to graft strips 128 and 130 . The planar graft strips 128 and 130 may consist of multiple layers of graft material that have been laminated together to form a graft strip thereof. Side portion 136 of planar graft strip 128 abuts side portion 138 of planar graft strip 130 along a lengthwise portion of assembly strip 124 to permit formation of a first seam on one side of assembly strip 124 . Similarly, side portion 132 of planar graft strip 128 abuts side portion 134 of planar graft strip 130 to permit formation of a second seam on the other side of assembly strip 124 . Such seams may be sealed by the aforementioned techniques. Planar graft strips 128 and 130 and planar wire 126 are substantially, as depicted in FIG. 5, coplanar. Upon sealing said seams, assembly strip 124 is formed as a pre-assembly strip for use as an intraluminal device. As depicted in FIG. 6, planar graft strip 128 and 130 are positioned so that each layer is substantially over one and the other. In an alternate embodiment planar graft strips 128 and 130 could be positioned so that one strip is offset from the other strip. Offsetting the layers is one technique for controlling the thickness of the final tubular graft and stent device because such an assembly strip can be helically wound with multiple overlaps of the strip. Furthermore, the amount of planar graft material forming an overlap can also be controlled. Such overlapping techniques are used to adjust flexibility, strength, thickness and bond integrity of the tubular graft/stent assembly. FIGS. 7 and 8 depict strip assembly 124 that has been helically wound. Assembly strip 124 is helically wound on a mandrel to form a substantially continuous stent/graft structure 140 . In a preferred embodiment, the stent/graft structure 140 is tubular with a generally spherical cross-section. Other cross-sectional shapes, such as, but not limited to, oval, may suitably be used. Planar graft strip 128 forms an exterior surface 142 of the tubular stent/graft structure 140 . Planar graft strip 130 forms an interior or luminal surface 144 of the tubular stent/graft structure 140 . Strip assembly 124 is helically wound on a mandrel so that successive helical windings create overlaps with adjacent portions of strip assembly 124 . A portion of planar graft strip 128 abuts a portion of planar graft strip 130 on each successive helical winding to create the overlaps. Such overlaps form a seam which can be sealed by aforementioned techniques. Upon sealing said seam, the tubular stent/graft structure 140 becomes a substantially fluid tight conduit. FIG. 9 depicts a method for helically winding planar assembly strips. Assembly strip 100 is helically wound about mandrel 146 to form a tubular stent/graft structure 118 with overlaps of the assembly strip 100 that form a seam. The aforementioned techniques for sealing overlaps in successive helical windings are used to form a tight fluid seam. After such seam is sealed, structure 118 is removed from mandrel 146 . FIGS. 10 and 11 depict a strip assembly 148 for forming another embodiment of a stent/graft apparatus of the present invention. Strip assembly 148 comprises planar graft strip 150 and planar wire 152 . Planar wire 152 , as depicted in FIG. 11, is disposed in substantially abutting relation to planar side 154 of the graft strip 150 . Furthermore, planar wire 152 is disposed in a substantially straight lengthwise pattern along the length of the graft strip 150 . Planar wire 152 is fixed onto the planar side 154 by aforementioned techniques. The straight-lengthwise pattern of planar wire 152 provides for, among other things, flexibility and longitudinal adjustability of the tubular intraluminal device formed therefrom by helically winding techniques. As depicted in FIGS. 12 and 13, assembly strip 148 may be helically wound on a mandrel to form a substantially tubular and continuous stent/graft structure 158 with a generally spherical cross-section. As depicted in FIG. 13, which is a view of cross-section 13 — 13 of the tubular stent/graft structure 158 , a portion of planar side 154 of assembly strip 148 abuts a portion of planar side 156 of assembly strip 148 on each successive wind to create overlaps in strip assembly 148 . Such overlaps form a seam. Upon sealing said seam by aforementioned techniques, the tubular stent/graft structure 158 becomes a substantially fluid tight conduit. As depicted in FIGS. 14 and 15, the assembly strip 148 may be helically wound so that successive windings do not overlap, thereby forming a tubular stent/graft structure 160 without overlapping adjacent graft strip portions. Such non-overlapping windings allow the tubular stent/graft structure 160 , among other things, to be longitudinally adjustable through use of either a self-expanding mechanism or through a pulling or pushing action by a physician, in well-known fashion. Other embodiments of longitudinally adjustable intraluminal devices are shown in FIGS. 16 through 21. As depicted in FIGS. 16 and 17, assembly strip 162 comprises a planar graft strip 164 and a planar ribbon stent strip 166 . The planar ribbon stent strip 166 is disposed in substantially abutting relation, to the planar graft strip 164 . Planar ribbon stent strip 166 may be secured to a surface of the planar graft strip 164 by aforementioned techniques. Upon helically winding assembly strip 162 on a mandrel, a tubular stent/graft structure 168 , as depicted in FIG. 18, is formed without overlapping adjacent graft strip portions. FIGS. 19 and 20 depict planar wire 174 which undulates along planar side 176 of planar graft strip 172 . Planar wire 174 extends or protrudes beyond edges 178 and 180 of the planar strip 172 . Upon helically winding assembly strip 170 , a tubular stent/graft structure 182 without overlapping adjacent graft strip portions, as depicted in FIG. 21, is formed. Tubular stent/graft structures 168 and 182 are, among other things, longitudinally adjustable because no seals are formed at adjacent graft strip portions of the tubular structures. As depicted in FIG. 22, assembly strip 184 may be helically would on a mandrel 188 to form a tubular stent/graft structure 186 , where adjacent portions of assembly strip 184 , are proximally located to one end and the other, or even overlap one and the other. The tubular stent/graft structure 186 may be longitudinally expanded to form tubular stent/graft structure without adjacent overlapping graft strip portions, as depicted in FIG. 21 . Furthermore, the tubular stent/graft structure 182 is radially adjustable because of the undulated planar stent wire 174 . FIGS. 23 through 34 depict additional embodiments of the present invention for forming fluid tight intraluminal devices. As depicted in FIGS. 23 and 24, assembly strip 190 comprises planar graft strips 192 and 194 . The planar graft strip 192 abuts the overlapping planar ribbon stent strip 194 and may be disposed thereon by aforementioned techniques. As depicted in FIG. 25, a continuous tubular stent/graft structure 196 may be formed by helically winding assembly strip 190 . Successive helical windings on a mandrel create overlaps of adjacent portions of the graft strip 192 and the planar ribbon stent strip 194 , which may be sealed by aforementioned techniques to form fluid tight conduits. As depicted in FIGS. 27-30, an assembly strip 198 may be formed from planar graft strip 200 and planar ribbon stent strip 202 . The planar ribbon stent strip 202 contains cuffs 204 and 206 that abut portions of the planar graft strip 200 . Upon fixing the cuffs 204 and 206 to the planar graft strip 200 by aforementioned techniques, the assembly strip 198 is formed. A continuous structure 208 , as depicted in FIG. 29, may be formed by successively winding assembly strip 198 on a mandrel in a manner where side portions of the planar graft strip 200 and the planar ribbon stent strip 202 abut with each successive winding, thereby forming a seam. Such a seam may be sealed by the aforementioned techniques to form a fluid tight conduit. Fluid tight conduits for use as intraluminal devices may be formed where the interior or luminal surface is substantially continuous, such as structure 210 as depicted in FIG. 32, or where the exterior surface is substantially continuous, such as structure 220 as depicted in FIG. 34 . Such devices with substantially continuous luminal and exterior surfaces may be formed by sealing overlaps formed by helically winding assembly strips 212 and 222 , respectively. The continuity of either the luminal or external surface is controlled by altering the planar ribbon stent strips, e.g., stent strips 216 and 226 , as depicted in FIGS. 31 and 33. For example, planar ribbon stent strip 216 has a longitudinal fold 218 along one of its sides. The fold 218 is configured so that a portion of the fold 218 abuts a portion of planar graft strip 214 on each successive helical winding to allow the remaining portions of planar ribbon stent strip 216 to form tubular structure with a substantially continuous luminal surface. An intraluminal device with a substantially smooth and continuous exterior surface may be formed from assembly strip 222 . As depicted in FIG. 33, the assembly strip 222 consists of a planar graft strip 224 and a planar ribbon stent strip 226 . Planar stent strip 226 contains a longitudinal fold 228 along one side of its lengthwise portion, a longitudinal fold 230 along the other side of its lengthwise portion. Upon helically wind the assembly strip 222 , the continuous tubular stent/graft structure 220 is formed. As depicted in FIG. 35, which is a cross-sectional view of a portion of structure 220 , longitudinal folds 228 and 230 overlap one and the other on each adjacent helical winding. Side portions of planar graft strip 224 also abut one and the other on each adjacent helical winding to form a substantially continuous and smooth exterior surface. The non-woven polymeric graft material may be formed by any conventional method provided the method allows for a porous surface structure to remain or be created. For example, extrusion processes such as ram extrusion; polymeric casting techniques such as solvent casting and film casting; molding techniques such as blow molding, injection molding and rotational molding; and other thermoforming techniques useful with polymeric materials may be employed and chosen to best serve the type of material used and specific characteristics of the membrane desired. Graft strips may also be formed by laminating multiple layers of graft material. The preferred membrane material of the present invention is ePTFE, although other thermoformable polymeric materials such as porous polyurethane and the like may be employed. The orientation of the fibers forming such polymeric materials can be varied to have the orientation of the fibers in an axial direction of the tubular structure, a longitudinal orientation or some combination thereof. The porous membranes of the present invention need not be structurally sufficient per se to withstand the pressures of blood flow and may be used merely as thin covers or liners for the stents and other devices in applications where dislodging of plaque debris and/or regrowth of the occlusion through the stent wall is of concern. Thus, in one embodiment, the membrane may have the structural integrity of a typical endoprosthesis or vascular graft, and in another embodiment the membrane may be of a thinner wall thickness than a typical vascular graft, but sufficient in thickness to serve as a prophylactic liner or cover against the aforementioned debris. The stent may be made from a variety of materials including stainless steel, titanium, platinum, gold and other bio-compatible metals. Thermoplastic materials which are inert in the body may also be employed. Shaped memory alloys having superelastic properties generally made from specific ratios of nickel and titanium, commonly known as nitinol, are among the preferred stent materials. Various stent types and stent constructions may be employed in the invention. Among the various stents useful include, without limitation, self-expanding stents and balloon expandable extents. The stents may be capable of radially contracting, as well and in this sense can best be described as radially distensible or deformable. Self-expanding stents include those that have a spring-like action which causes the stent to radially expand, or stents which expand due to the memory properties of the stent material for a particular configuration at a certain temperature. Nitinol is one material which has the ability to perform well while both in spring-like mode, as well as in a memory mode based on temperature. Other materials are of course contemplated, such as stainless steel, platinum, gold, titanium and other biocompatible metals, as well as polymeric stents. The configuration of the stent may also be chosen from a host of geometries. For example, wire stents can be fastened into a continuous helical pattern, with or without a wave-like or zig-zag in the wire, to form a radially deformable stent. Individual rings or circular members can be linked together such as by struts, sutures, welding or interlacing or locking of the rings to form a tubular stent. Tubular stents useful in the present invention also include those formed by etching or cutting a pattern from a tube. Such stents are often referred to as slotted stents. Furthermore, stents may be formed by etching a pattern into a material or mold and depositing stent material in the pattern, such as by chemical vapor deposition or the like. The assembly strips of the present invention are not limited to the use of one stent wire positioned onto an assembly strip. A plurality of stent wires may be fixed onto assembly strips to achieve desired stent patterns. Various changes in modifications may be made to the invention, and it is intended to include all such changes and modifications as come within the scope of the invention and as set forth in the following claims.
The present invention relates to a support structure/membrane composite device which includes a support structure, such as a radially expandable stent, a porous non-textile polymeric membrane adjacent to said stent and a thermoplastic anchor means attaching said stent to said porous non-textile polymeric membrane. The porous non-textile polymeric membrane is preferably made from expandable fluoropolymer materials. The anchoring means is a thermoplastic material which is dissolvable at the interface between the support structure and membrane by a suitable solvent which wets the membrane surface and deposits the thermoplastic material within the pores of the membrane. Methods of preparing the device are also disclosed.
0
TECHNICAL FIELD [0001] The present invention relates to the technical field of cyclic utilization of waste concrete, and in particular to an I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps and construction process of such beam. BACKGROUND [0002] I-shaped steel reinforced concrete beam refers to a beam-like member formed by arranging longitudinal bars, waist bars and stirrups around a rolled or welded I-shaped steel then pouring concrete. Since the I-shaped steel reinforced concrete beam has advantages such as high rigidity and high bearing capacity, it has been widely used in real projects. It can be seen from the structural mechanics principle and a large number of structural design examples that, the I-shaped steel reinforced concrete beam in the actual structure only bears positive bending moment near its min-span under the combined effect of vertical load and horizontal load. That is, near the min-span, bottom flange plate of the I-shaped steel is in tension while the top flange plate is in compression. Since the economical efficiency of the compression of the concrete is better than that of the compression of the steel, and the concrete surrounding the top flange plate near the min-span can take on the role of bearing compression. Thus in the case of bearing capacity of the beam remains about the same, the I-shaped steel reinforced concrete beam may be further optimized by reducing min-span parts of the top flange plate of the conventional I-shaped steel, and thereby the purpose of saving steel is realized, but such technology is rarely seen by now. [0003] Since natural sand and gravel mining destroys the environment and the reserves are dwindling, waste concrete, as a valuable “special resource”, its recycle use has attracted more and more attention at home and abroad. Compared with recycled coarse aggregate and recycled fine aggregate, adopting demolished concrete lumps with larger scale can greatly simplify recycling process of the waste concrete. However, for the conventional I-shaped steel reinforced concrete beam, due to the obstruction of the continuous top flange plate having penetrating length, putting of the demolished concrete lumps from top to bottom in the pouring process of the beam is very difficult, which is an urgent problem to be solved. In the present invention, a gap of a top flange plate of the I-shaped steel having discontinuous top flange can be just used for putting in the demolished concrete lumps, which can yet be regarded as an effective method for solving this problem. [0004] To sum up, problems exist in the prior arts, such as economical efficiency of the conventional I-shaped steel reinforced concrete beam that needs to be improved, and failure of cyclic utilization of demolished concrete lumps in the conventional I-shaped steel reinforced concrete beam due to difficulty in putting. SUMMARY OF THE INVENTION [0005] The object of the present invention is to overcome the deficiencies of the prior arts. On one hand, no min-span part of a top flange plate of conventional I-shaped steel is required, and in the case of bearing capacity of a beam remains about the same, the purpose of saving steel is realized. On the other hand, a gap of a discontinuous top flange plate can be just used for putting in demolished concrete lumps, and thereby problem of failure of cyclic utilization of demolished concrete lumps in a conventional I-shaped steel reinforced concrete beam due to difficulty in putting. [0006] Another object the present invention is to provide a construction process of an I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps. [0007] The technical solution adopted in the present invention to achieve the above-mentioned object is as follows: [0008] An I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps, comprising an I-shaped steel, and longitudinal bars, stirrups and waist bars located outside the I-shaped steel, characterized in that: it further comprises fresh concrete and demolished concrete lumps, which are poured alternately. The I-shaped steel is the I-shaped steel having discontinuous top flange, which consists of a bottom flange plate, a web and a discontinuous top flange plate. The top flange plate and the bottom flange plate are parallel and both perpendicular to the web. The web is located between the top flange plate and the bottom flange plate and welded with the top flange plate and the bottom flange plate respectively. [0009] Further optimized, the discontinuous top flange plate consists of two steel plates located at both sides of the I-shaped steel. The steel plates are rectangle steel plates or trapezoid steel plates. The two steel plates have a same length that is one third of a length of the I-shaped steel. The trapezoid steel plate has a long side located at an end portion of the I-shaped steel. The trapezoid steel plate has a width of a short side no less than a quarter of a width of the long side. [0010] Further optimized, the demolished concrete lumps are waste concrete lumps after demolishing old buildings, structures, roads, bridges or dams and removing protective layers and all or part of steel reinforcements. [0011] Further optimized, the fresh concrete is a natural aggregate concrete or a recycled aggregate concrete, and has a compressive strength no less than 30 MPa. [0012] Further optimized, the demolished concrete lump has a characteristic size no less than 100 mm, and a mass ratio of the demolished concrete lump and the fresh concrete is 1:4˜1:1. [0013] A construction process of the above-described I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps, which comprises following steps: [0014] (1) forming the I-shaped steel having discontinuous top flange by welding a bottom flange plate, a web and two steel plates in advance, setting up a bottom die of the compound concrete beam first, after hoisting the I-shaped steel with discontinuous top flange in position, binding longitudinal bars, waist bars and stirrups, and finally setting up a side die; [0015] (2) fully wetting demolished concrete lumps in advance, pouring fresh concrete with a thickness of 20˜30 mm inside a cavity formed by the bottom die and the side die first, then putting a layer of the wet demolished concrete lumps in a gap between the two rectangle steel plates or trapezoid steel plates, and stirring artificially so that the demolished concrete lumps are uniformly distributed inside the cavity formed by the bottom die and the side die, then pouring a layer of fresh concrete and fully vibrating, so that the demolished concrete lumps and the fresh concrete are uniformly mixed into one; repeatedly and alternately pouring the fresh concrete and the demolished concrete lumps until pouring is finished. [0016] Compared with the prior arts, the present invention has following advantages: [0017] (1) No min-span part of a top flange plate of conventional I-shaped steel is required, and in the case of bearing capacity of a beam remains about the same, the purpose of saving steel is realized. [0018] (2) Utilizing a gap of the discontinuous top flange plate for putting in the demolished concrete lumps, thereby problem of failure of cyclic utilization of demolished concrete lumps in a conventional I-shaped steel reinforced concrete beam due to difficulty in putting is solved. [0019] (3) Using the demolished concrete lumps for pouring, greatly simplifies treating processes such as crushing, screening and purifying during cyclic utilization of the waste concrete, which saves a large amount of manpower, time and energy, and may realize effective cyclic utilization of the waste concrete. BRIEF DESCRIPTION OF THE DRAWINGS [0020] FIG. 1 a , FIG. 1 b and FIG. 1 c are schematic views of transverse section, A-A section and B-B section of the beam according to Embodiment 1 of the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps of the present invention. [0021] FIG. 2 a , FIG. 2 b and FIG. 2 c are schematic views of transverse section, A-A section and B-B section of the beam according to Embodiment 2 of the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps of the present invention. [0022] FIG. 3 a , FIG. 3 b , FIG. 3 c are schematic views of transverse section, A-A section and B-B section of the beam according to Embodiment 3 of the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0023] The present invention is further described in detail below in combination with embodiments and accompanying drawings, but implementations of the present invention are not limited thereto. It should be pointed out that, if there is a process that is not specifically described in detail below, those skilled in the art can realize it with reference to the prior arts. Embodiment 1 [0024] See FIG. 1 a , FIG. 1 b and FIG. 1 c , the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps according to the present invention comprising a discontinuous top flange plate 1 , a web 2 , a bottom flange plate 3 , demolished concrete lumps 4 , fresh concrete 5 , stirrups 6 , longitudinal bars 7 , and waist bars 8 . The recycled compound concrete beam has a rectangular section, with a beam depth of 850 mm, a beam width of 550 mm, and a beam length of 8100 mm. The discontinuous top flange plate is two 2700 mm×300 mm×12 mm rectangle steel plates. The web and the bottom flange plate are the same as the web and bottom flange plate of a conventional I-shaped steel having a section size of 500 mm×300 mm×10 mm×12 mm, respectively, both of which are Q235 steel material, and have a measured yield strength of 255.8 MPa and an ultimate strength of 330.7 MPa. The fresh concrete has a cube compressive strength of 42.2 MPa, while the demolished concrete lump has a cube compressive strength of 37.6 MPa, and after combination, the cube compressive strength is 40.67 MPa. Horizontal stirrup adopts HRB335-grade steel reinforcement with a diameter of 8 mm, with an interval at an encrypted area being 150 mm, and an interval at a non-encrypted area being 200 mm. The longitudinal bar adopts HRB335-grade steel reinforcement with a diameter of 25 mm, with 2 longitudinal bars being arranged at an upper part, and 6 longitudinal bars being arranged at a lower part. The waist bar adopts HRB335-grade steel reinforcement with a diameter of 8 mm, being arranged at both sides of the I-shaped steel, with each side being 3 waist bars. The demolished concrete lumps are waste concrete lumps after demolishing an old building and removing protective layers and all steel reinforcements. The fresh concrete is a natural aggregate concrete. The demolished concrete lump has a characteristic size of 100˜200 mm, and a mass ratio of the demolished concrete lump and the fresh concrete is 1:2. [0025] A construction process of the above-described I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps, which comprises following steps: [0026] (1) forming the I-shaped steel having discontinuous top flange by welding a bottom flange plate, a web and two rectangle steel plates in advance, setting up a bottom die of the compound concrete beam first, after hoisting the I-shaped steel having discontinuous top flange in position, binding longitudinal bars, waist bars and stirrups, and finally setting up a side die; [0027] (2) fully wetting demolished concrete lumps in advance, pouring fresh concrete with a thickness of 20 mm inside a cavity formed by the bottom die and the side die first, then putting a layer of the wet demolished concrete lumps in a gap between the two rectangle steel plates, and stirring artificially so that the demolished concrete lumps are uniformly distributed inside the cavity formed by the bottom die and the side die, then pouring a layer of fresh concrete and fully vibrating, so that the demolished concrete lumps and the fresh concrete are uniformly mixed into one; repeatedly and alternately pouring the fresh concrete and the demolished concrete lumps until pouring is finished. [0028] For the purpose of comparison, a conventional I-shaped steel having a section size of 500 mm×300 mm×10 mm×12 mm and same material, same longitudinal bars, stirrups and waist bars, and natural aggregate concrete having a cube compressive strength of 40.67 MPa are taken, to produce a composite beam with internal conventional I-shaped steel. It is eventually found that the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps in the present embodiment has a flexural bearing capacity of normal section of 1846 kN·m, while the composite beam with internal conventional I-shaped steel has a flexural bearing capacity of normal section of 1932 kN·m. By calculating, it can be seen that the flexural bearing capacity of normal section of the two beams is only 4.4% difference, but the former not only saves 10.03% of steel, but also puts 1.26 cubic meters of demolished concrete lumps into recycling. Embodiment 2 [0029] See FIG. 2 a , FIG. 2 b and FIG. 2 c , the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps according to the present invention comprising a discontinuous top flange plate 1 , a web 2 , a bottom flange plate 3 , demolished concrete lumps 4 , fresh concrete 5 , stirrups 6 , longitudinal bars 7 and waist bars 8 . The recycled compound concrete beam has a rectangular section, with a beam depth of 850 mm, a beam width of 550 mm, and a beam length of 8100 mm. The discontinuous top flange plate is two (150 mm+300 mm)×2100 mm×12 mm trapezoid steel plates. The web and the bottom flange plate are the same as the web and bottom flange plate of a conventional I-shaped steel having a section size of 500 mm×300 mm×10 mm×12 mm, respectively, which are Q235 steel material, and have a measured yield strength of 255.8 MPa, and an ultimate strength of 330.7 MPa. The fresh concrete has a cube compressive strength of 42.2 MPa, while the demolished concrete lump has a cube compressive strength 37.6 MPa, and after combination, the cube compressive strength is 40.67 MPa. Horizontal stirrup adopts HRB335-grade steel reinforcement with a diameter of 8 mm, with an interval at an encrypted area being 150 mm, and an interval at a non-encrypted area being 200 mm. The longitudinal bar adopts HRB335-grade steel reinforcement with a diameter of 25 mm, with 2 longitudinal bars being arranged at an upper part, and 6 longitudinal bars being arranged at a lower part. The waist bar adopts HRB335-grade steel reinforcement with a diameter of 8 mm, being arranged at both sides of the I-shaped steel, with each side being 3 waist bars. The demolished concrete lumps are waste concrete lumps after demolishing an old building and removing protective layers and all steel reinforcements. The fresh concrete is a natural aggregate concrete. The demolished concrete lump has a characteristic size of 100˜200 mm, and a mass ratio of the demolished concrete lump and the fresh concrete is 1:2. [0030] A construction process of the above-described I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps, which comprises following steps: [0031] (1) Forming the I-shaped steel having discontinuous top flange by welding a bottom flange plate, a web and two trapezoid steel plates in advance, setting up a bottom die of the compound concrete beam first, after hoisting the I-shaped steel having discontinuous top flange in position, then binding longitudinal bars, stirrups and waist bars, and finally setting up a side die; [0032] (2) fully wetting demolished concrete lumps in advance, pouring fresh concrete with a thickness of 30 mm inside a cavity formed by the bottom die and the side die first, then putting a layer of the wet demolished concrete lumps in a gap between the two trapezoid steel plates, and stirring artificially so that the demolished concrete lumps are uniformly distributed inside the cavity formed by the bottom die and the side die, then pouring a layer of fresh concrete and fully vibrating, so that the demolished concrete lumps and the fresh concrete are uniformly mixed into one; repeating the above-described process until pouring is finished. [0033] For the purpose of comparison, a conventional I-shaped steel having a section size of 500 mm×300 mm×10 mm×12 mm and same material, same longitudinal bars, stirrups and waist bars, and natural aggregate concrete having a cube compressive strength of 40.67 MPa are taken, to produce a composite beam with internal conventional I-shaped steel. It is eventually found that the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps in the present embodiment has a flexural bearing capacity of normal section of 1846 kN·m, while the composite beam with internal conventional I-shaped steel has a flexural bearing capacity of normal section of 1932 kN·m. By calculating, it can be seen that the flexural bearing capacity of normal section of the two beams is only 4.4% difference, but the former not only saves 15.05% of steel, but also puts 1.26 cubic meters of demolished concrete lumps into recycling. Embodiment 3 [0034] See FIG. 3 a , FIG. 3 b and FIG. 3 c , the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps according to the present invention comprising a discontinuous top flange plate 1 , a web 2 , a bottom flange plate 3 , demolished concrete lumps 4 , fresh concrete 5 , stirrups 6 , longitudinal bars 7 and waist bars 8 . The recycled compound concrete beam has a rectangular section, with a beam depth of 850 mm, a beam width of 550 mm, and a beam length of 8100 mm. The discontinuous top flange plate is two (75 mm+300 mm)×2100 mm×12 mm trapezoid steel plates. The web and the bottom flange plate are the same as the web and bottom flange plate of a conventional I-shaped steel having a section size of 500 mm×300 mm×10 mm×12 mm, respectively, which are Q235 steel material, and have a measured yield strength of 255.8 MPa, and an ultimate strength of 330.7 MPa. The fresh concrete has a cube compressive strength of 42.2 MPa, while the demolished concrete lump has a cube compressive strength of 37.6 MPa, and after combination, the cube compressive strength is 41.05 MPa. Horizontal stirrup adopts HRB335-grade steel reinforcement with a diameter of 8 mm, with an interval at an encrypted area being 150 mm, and an interval at a non-encrypted area being 200 mm. The longitudinal bar adopts HRB335-grade steel reinforcement with a diameter of 2 5mm, with 2 longitudinal bars being arranged at an upper part, and 6 longitudinal bars being arranged at a lower part. The waist bar adopts HRB335-grade steel reinforcement with a diameter of 8 mm, being arranged at both sides of the I-shaped steel, with each side being 3 waist bars. The demolished concrete lumps are waste concrete lumps after demolishing an old building and removing protective layers and all steel reinforcements. The fresh concrete is a natural aggregate concrete. The demolished concrete lump has a characteristic size of 100˜200mm, and a mass ratio of the demolished concrete lump and the fresh concrete is 1:3. [0035] A construction process of the above-described I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps, which comprises following steps: [0036] (1) Forming the I-shaped steel having discontinuous top flange by welding a bottom flange plate, a web and two trapezoid steel plates in advance, setting up a bottom die of the compound concrete beam first, after hoisting the I-shaped steel having discontinuous top flange in position, then binding longitudinal bars, stirrups and waist bars, and finally setting up a side die; [0037] (2) fully wetting demolished concrete lumps in advance, pouring fresh concrete with a thickness of 20 mm inside a cavity formed by the bottom die and the side die first, then putting a layer of the wet demolished concrete lumps in a gap between the two trapezoid steel plates, and stirring artificially so that the demolished concrete lumps are uniformly distributed inside the cavity formed by the bottom die and the side die, then pouring a layer of fresh concrete and fully vibrating, so that the demolished concrete lumps and the fresh concrete are uniformly mixed into one; repeating the above-described process until pouring is finished. [0038] For the purpose of comparison, a conventional I-shaped steel having a section size of 500 mm×300 mm×10 mm×12 mm and same material, same longitudinal bars, stirrups and waist bars, and natural aggregate concrete having a cube compressive strength of 41.05 MPa are taken, to produce a composite beam with internal conventional I-shaped steel. It is eventually found that the I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps in the present embodiment has a flexural bearing capacity of normal section of 1852 kN·m, while the composite beam with internal conventional I-shaped steel has a flexural bearing capacity of normal section of 1936 kN·m. By calculating, it can be seen that the flexural bearing capacity of normal section of the two beams is only 4.34% difference, but the former not only saves 17.56% of steel, but also puts 0.95 cubic meters of demolished concrete lumps into recycling. [0039] The above are preferred implementations of the present invention, but the implementations of the present invention are not limited by the above content. Any other changes, modifications, substitutions, combinations and simplifications that are not deviated from the spirit and principles of the present invention should be equivalent replacements, which are included within the scope of protection of the present invention.
An I-shaped steel with discontinuous top flange reinforced compound concrete beam containing demolished concrete lumps and a construction process thereof. The beam comprises an I-shaped steel having discontinuous top flange, longitudinal bars ( 7 ), stirrups ( 6 ), waist bars ( 8 ), fresh concrete ( 5 ), and demolished concrete lumps ( 4 ). The I-shaped steel having discontinuous top flange consists of a bottom flange plate ( 3 ), a web ( 2 ) and a discontinuous top flange plate (I). The discontinuous top flange plate ( 1 ) consists of two rectangle steel plates or trapezoid steel plates located at both sides of the I-shaped steel. The two steel plates have a same length that is one third of a length of the I-shaped steel. The trapezoid steel plate has a width of a short side no less than a quarter of a width of the long side. The recycled compound concrete beam saves steel, fully uses the demolished concrete lumps, and is convenient to construct.
4
This is a continuation of application Ser. No. 460,213, filed Jan. 24, 1983, now abandoned. BACKGROUND OF THE INVENTION A. Field of the Invention This invention relates to travelers useful in ring spinning of staple into yarn. More particularly, the invention relates to specially designed travelers which permit ring spinning frames to be operated under conditions that provide low twist yarn of increased bulk at higher yarn throughputs (productivity) than is otherwise possible using conventional travelers. B. Description of the Prior Art Carpet staple in the form of sliver (a loosely assembled strand of staple fibers without twist) is coverted to useful yarn on ring spinning frames. The frames consist of a plurality of positions or stations each of which processes sliver. Each position comprises drafting rolls, a ring-and-traveler take-up mechanism, and a bobbin mounted on a rotatable spindle. The drafting of the sliver and the twisting and winding of the yarn onto the bobbin proceed sequentially and continuously. Travelers used in spinning carpet yarns are usually ear-shaped and range in weight from 3.0 grains (0.2 grams) for a 6's cotton count to 18.0 grains (1.2 grams) for a 11/2 cotton count. Conventionally, travelers used in spinning the coarser counts are not only heavier, but also taller and wider in cross-section. In commercial practice, ring spinning frames are operated under conditions which maximize the productivity of the frames. Such conditions include operating the spindle at its highest practical mechanical speed and then adjusting the peripheral speed of the delivery rolls so that just enough twist is inserted in the sliver to keep the winding tension from pulling the sliver apart before it can be would onto the bobbin. For example, under such conditions the spinning of a 21/2 cotton count staple yarn requires about 4.25 turns of twist per inch (167.3 turns per m) which corresponds to a processing speed of about 40 ypm (36.8 mpm). While a reduction in twist level in the yarn would improve the bulk of the yarn, such a reduction cannot be achieved on a conventional ring spinning frame without sacrificing productivity to a trade-off the industry is not willing to make. SUMMARY OF THE INVENTION It is an object of the present invention to provide a means which permits a conventional ring spinning frame to be operated under conditions such that a yarn of reduced twist level and increased bulk is produced at higher productivity than is otherwise possible. The object of the invention is accomplished by providing a traveler for use on conventional carpet ring spinning frames characterized in that the radius of curvature (Ry) of the inside edge of the traveler which is in contact with the yarn during spinning (yarn contact edge) is less than 20 mils (0.5 mm). The traveler of the invention permits the front rolls (delivery rolls) of spinning frames to be operated at higher peripheral speeds than is possible if conventional carpet ring spinning frame travelers are used. Travelers useful in practicing the invention generally have a weight in excess of 3.0 grains (e.g. 3.0 to 18.0 grains) and usually in excess of 5.0 grains. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a schematic representation of a conventional ring spinning frame. FIG. 2 is a side elevation of a traveler of the present invention. FIG. 3 is an enlarged cross-section taken along line III--III in FIG. 2 and shows the cross-section of the yarn contact edge of the traveler. FIGS. 4 and 5 each show an alternative cross-section to that shown in FIG. 3. DESCRIPTION OF THE PREFERRED EMBODIMENTS The travelers of this invention are capable of increasing the productivity of conventional carpet ring spinning frames and providing spun yarn of a reduced twist level and increased bulk. A typical ring-spinning frame useful for producing carpet yarn is shown in FIG. 1. Referring to FIG. 1, the frame comprises a pair of driven nip rolls 3 which serve as feed rolls, an apron drafting system 4, having two pair of nip rolls (referred to as middle rolls), a pair of driven nip rolls 5 (referred to as front rolls or delivery rolls), a guide 6, traveler 7, ring 8, and spindle 9, and bobbin 10 mounted on spindle 9. Each pair of nip rolls is driven at a peripheral speed correlated to give the desired drafting (e.g. 20 times) and throughput. In operation of the frame, strand 1 in the form of a sliver is passed over guide roll 2 through the drafting zone and is delivered by delivery rolls 5 to traveler 7 via guide 6. The hook-like ends of traveler 7 engage the outside face of ring 8 and retain traveler 7 during processing despite the up and down motion of ring 8 relative to bobbin 10 and the traveling of traveler 7 around ring 8 at high speeds. Strand 1, now in the form of a twisted yarn, makes a partial wrap around the inside edge of traveler 7 enroute to the bobbin 10. The wrap is made by the passage of the yarn through the opening defined by ring 7 and traveler 8. Traveler 7 rotates concentrically around spindle 9 at a speed less than the rotational speed of the spindle 9 in order to allow the yarn to be wound onto bobbin 10. The rotational path of traveler 7 around spindle 9 inserts twist in sliver 1 (one turn of twist per rotation of traveler 7) which backs up from traveler 7 to the nip of delivery rolls 5. Sufficient twist must be inserted in sliver 1 to keep it from pulling apart during the spinning process. (When a strand is pulled apart during operation of the frame for whatever reason, such occurrences are referred to as "ends down".) Using a conventional traveler and operating spindle 10 at its maximum practical speed, there is a maximum speed (delivery speed) at which yarn can be delivered to traveler 7 without causing "ends down". By replacing a conventional carpet ring spinning frame traveler with the specially designed traveler of the present invention, the delivery speed of the sliver can be significantly increased, for example, by a factor of two or more. This has a two-fold effect. It increases the productivity of the frame by a corresponding factor and also reduces the twist level of the resulting yarn by approximately the same factor. Reducing the twist level increaes the bulk of the yarn. The travelers of the present invention are characterized in that the yarn contact edge thereof has a radius of curvature (Rc) less than 20 mils (0.50 mm), for example 10 to 20 mils (0.25 to 0.50 mm). In general, reducing Rc permits the speed of the delivery rolls to be increased without causing ends down. However, the radius of curvature of the yarn contact edge of the traveler should not be so small as to provide a razor-like edge which would tend to cut the yarn. A preferred traveler of the present invention is shown in FIG. 2. Referring to FIG. 2, the ear-shaped traveler 20 has a main body section 21 terminating in hook ends 22 and 23 and a wedge-shaped yarn contact section 24 having a yarn contact edge 25. The cross-section of section 24 is shown in FIG. 3. When the traveler is in use, edge 25 is in contact with staple yarn 26 as shown in FIG. 3. Instead of having the wedge-shaped yarn contact section 24 shown in FIG. 3, the traveler alternatively may be fabricated to have a circular-shaped (FIG. 4) or a rectangular-shaped (FIG. 5) yarn contact section or any other shape, providing that the yarn contact edge 25 thereof has a radius of curvature of less than 20 mils. The travelers may be constructed from conventional materials such as plastic or metal. Preferably, the travelers of the present invention differ from conventional travelers only in the shape of the yarn contact section of the traveler and, therefore, may be of a conventional shape, e.g., ear-shaped. EXAMPLE 1 This example demonstrates the advantages gained by using a traveler designed in accordance with the present invention. In the example, spinning runs are carried out using one position of a conventional Whitin NW ring spinning frame, in which 70-grain per yard (4.9 grams per meter) sliver composed of nylon 66 staple fibers having a length of 71/2 inches (19.05 cm), a denier of 15 and an average of 9 crimps per inch (354 cpm) is converted to spun yarn having twist in the Z direction. The ring of the spinning frame has an inside diameter of 41/2 inches (11.4 cm). In certain of the spinning runs, a conventional ear-shaped plastic traveler is used. In other spinning runs the same traveler is used but it is modified to have a wedge-shaped yarn contact section resembling that of the traveler shown in FIG. 3. In each of the runs the spindle is operated at 5500 rpm and the front roll speed is adjusted to provide the lowest possible twist level in the final product without causing the yarn to break before it can be wound onto the bobbin. In runs where a conventionally-shaped traveler is used the lowest twist level that is achieved in the product (spun yarn) is about 4 turns per inch (157.5 turns per m). In contrast, in runs where a traveler of the present invention is used a twist level as low as 3 turns per inch (118.1 turns per m) in the product is obtained. In one run the yarn contact section of the traveler shaped in accordance with the invention is circular in cross-section (diameter=20 mils or 0.5 mm) having a radius of curvature of 10 mils (0.25 mm). The low twist yarns prepared using the travelers of the present invention are bulkier than the corresponding higher twist yarns prepared using conventional travelers. Moreover, when preparing the low twist yarns, the front rolls are operated at higher speeds, thereby increasing the productivity of the frame.
An improvement in the conventional process for converting sliver to carpet yarn on a ring spinning frame is described. The improvement increases the productivity of the frame and at the same time provides bulkier yarn. The improvement is achieved by utilizing a specially designed traveler which permits the frame to be operated at higher throughputs.
3
DESCRIPTION [0001] 1. Field of the Invention [0002] The invention relates to an optical rangefinder as used, for example, in surveying plots of ground and structures. [0003] 2. Prior Art [0004] Optical rangefinders of the generic type have long been known. However, the luminance of the usually used emitters having a laser diode as a light source is as a rule lower than will be permissible from the point of view of eye protection. Moreover, the light beam emitted by an individual laser diode usually has a disadvantageous, very elongated cross-section, which can lead to insufficient focusing onto the target and consequently to an inadequate luminous flux and measuring errors. For these reasons, the range and accuracy of measurement and reliability of measurement of rangefinders of the generic type will be less than desirable and in principle also possible. SUMMARY OF THE INVENTION [0005] It is the object of the invention to provide an optical rangefinder of the generic -type whose emitter has a high luminance and ensures good target illumination and high luminous flux at the target. [0006] The advantages achieved by the invention lie in particular in a decisive improvement in the range, i.e. in the maximum measured distance or, for a given range, an increase in the accuracy of measurement. These advantages are achieved with a relatively small emitter optical system, which makes it possible to keep the dimensions of the entire device small. BRIEF DESCRIPTION OF THE DRAWINGS [0007] The invention is explained in more detail below with reference to figures which merely represent the examples. [0008] [0008]FIG. 1 a shows a diagram of the emitter of a first embodiment of a rangefinder according to the invention, [0009] [0009]FIG. 1 b shows the beam cross-section of the emitter according to the first embodiment at the target, [0010] [0010]FIG. 2 a shows a diagram of the emitter of a second embodiment of a rangefinder according to the invention, [0011] [0011]FIG. 2 b shows the beam cross-section of the emitter according to the second embodiment at the target, [0012] [0012]FIG. 3 shows a diagram of the emitter of a third embodiment of a rangefinder according to the invention, [0013] [0013]FIG. 4 shows a diagram of the emitter of a fourth embodiment of a rangefinder according to the invention, [0014] [0014]FIG. 5 schematically shows the design of the emitter of a fifth embodiment of a rangefinder according to the invention and [0015] [0015]FIG. 6 shows the aperture of the collimator of the fifth embodiment of the rangefinder according to the invention and the beam cross-section at said collimator. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0016] An optical rangefinder according to the invention has an emitter and a receiver which, for example, may be composed in a known manner of an optical system and avalanche photodiodes as well as an electronic control and evaluation unit, likewise of known design, which controls the emission of light pulses by the emitter and evaluates the output signal of the receiver which receives the reflected light pulses. The distance measurement can be effected by transit time measurement or by the phase comparison method. Here, “light” is always to be understood as meaning that it is not limited to the visible range of the spectrum but also includes at least the infrared range. [0017] The emitter of a rangefinder according to the invention may have large differences in its basic design. In every case, however, it has (FIG. 1- 5 ) a collimator 1 and a light source arranged before said collimator and consisting in each case of at least two partial light sources, as well as a beam-collecting optical system 2 arranged in the beam path between the light source and the collimator. Each partial light source contains a laser diode, which is usually an edge emitter, or a plurality of such laser diodes arranged in succession in the direction of the emission edges. The wavelength common to all laser diodes is the infrared range, preferably from 850 nm to 980 nm, or 1550 nm. The cross-section of the light beam emitted by a laser diode can in each case be reduced parallel to the emission edge and increased transverse thereto by superposition by means of a beam-forming optical system arranged very close to the emission edge and based on light diffraction or refraction, and the light beam can thus be more highly focused. [0018] With wavelengths from 850 nm to 980 nm, the beam can be focused to a very narrow beam, which permits distance gradation with high lateral resolution. Wavelengths of about 1550 nm are also very advantageous because the upper limit of the permissible individual pulse energy of about 8 mJ, which is determined by eye safety, is a factor of about 16000 higher than at wavelengths from 630 nm to 980 nm. The at least partial use of this factor, which is possible according to the invention, permits a very substantial increase in the range or—at a given range—in the accuracy of measurement. [0019] According to the first diagram (FIG. 1 a ), the light source consists of two partial light sources 3 a,b arranged directly side by side. The beam-collecting optical system 2 is in the form of a collecting optical system 4 which is common to both partial light sources and collects partial beams 5 a,b emitted by said partial light sources in the object plane 6 of the collimator 1 . They enter the aperture of the collimator 1 in such a way that each individual partial beam 5 a,b substantially fills the aperture and therefore their cross-sections substantially overlap there. At the collimator 1 , the partial beams 5 a,b then diverge again, but only to such an extent that their cross-sections lie directly side by side at the target (FIG. 1 b ). The light beam emitted by the emitter has, at the target, a luminous flux which is approximately twice as great as that of a light beam emitted by an individual laser diode. [0020] According to the second diagram (FIG. 2 a ), the partial light sources 3 a,b are further apart. A separate collecting optical system 4 a;b which once again collects the partial beam 5 a or 5 b emitted by it in the object plane 6 of the collimator 1 is coordinated with each partial light source. The partial beams 5 a,b are incident side by side on the aperture of the collimator 1 , in such a way that they substantially completely fill said aperture and then form a parallel light beam of circular cross-section at the collimator 1 (FIG. 2 b ), which therefore has, at the target, not only approximately twice as high a luminous flux as a light beam emitted by individual laser diode, but also a more advantageous cross-section. [0021] According to the third diagram (FIG. 3), the partial light sources 3 a,b are arranged opposite one another, and the beam-collecting optical system 2 has collecting optical systems 4 a;b arranged after said partial light sources, as well as a prism 7 arranged between said optical systems and in the form of a diverter element. The prism 7 has two reflection surfaces 8 a,b which divert the partial light beams 5 a,b emitted by the partial light sources 3 a,b into a further, common collecting optical system 9 which collects them, in a manner similar to the light source according to the first diagram, in the object plane 6 of the collimator 1 and directs them to its aperture, where they substantially overlap. The beam cross-section corresponds to FIG. 1 b . The use of a diverter element makes it possible to arrange the partial light sources 3 a,b relatively far apart, which facilitates the cooling of the laser diodes. [0022] The fourth diagram (FIG. 4) corresponds substantially to the third one. The difference is in particular in the fact that the collecting optical systems 4 a,b , 9 are adjusted differently, in such a way that, similarly to the light source according to the second diagram, there is virtually no overlap of the partial light beams 5 a,b , but the aperture of the collimator 1 is filled by the partial beams 5 a,b incident on it side by side, and they then propagate at said collimator substantially parallel in such a way that the beam cross-section corresponds to FIG. 2 b . [0023] [0023]FIG. 5 shows, likewise schematically but in more detail, the structure of the emitter of a rangefinder according to the invention, which corresponds to a further diagram. In addition to a collimator 1 and a beam-collecting optical system 2 , it contains partial light sources 3 a,b , which emit partial beams 5 a,b of the same polarity which are oriented perpendicular to one another, and two further partial light sources 3 c,d , which likewise emit partial beams 5 c,d which are oriented perpendicular to one another and whose polarization is orthogonal to that of the partial beams 5 a,b . The partial light sources 3 a,b,c,d consist in each case of a laser diode 10 and a cylindrical lens 11 arranged a small distance away from said laser diode. A collecting optical system 4 a;b;c,d is arranged after each of the partial light sources 3 a,b,c,d . [0024] A plate 12 a which is half-mirrored and half-transparent so that it transmits the partial beam 5 a but diverts the partial beam 5 b in a direction parallel to the partial beam 5 a is arranged, as a first diverter element, after the collecting optical systems 4 a,b . The second diverter element arranged after the collecting optical system 4 c,d is, like the first diverter element, in the form of a half-mirrored and half-transparent plate 12 b which transmits the partial beam 5 c while it diverts the partial beam 5 d in a direction parallel to said partial beam 5 c . The partial beams 5 a,b on the one hand and 5 c,d on the other hand each reach, directly side by side, a polarization cube 13 , where the pairs of partial beams meet at right angles. The partial beams 5 a,b in each case partially overlap with the partial beams 5 c,d which are polarized orthogonal to them and are collected by a further collecting optical system 9 in the object plane 6 of the collimator 1 and directed onto its aperture, which is substantially filled in this way (FIG. 6). In the centre of the cross-shaped light spot is an approximately square spot of twice the luminance, where in each case two partial beams of orthogonal polarization overlap. [0025] Various modifications of the examples described are possible. Thus, in particular in the case of diagrams 1 to 4 , more than the two partial light sources shown can be used. The collection of partial beams by diverter elements can be cascaded for increasing the number of partial light sources, etc. Finally, it is also possible to use laser diodes having wavelengths of, in particular, from 600 nm to 1000 nm and in particular from 630 nm to 980 nm, which are outside the above-mentioned ranges. [0026] List of Reference Numerals [0027] [0027] 1 Collimator [0028] [0028] 2 Beam-collecting optical system [0029] [0029] 3 a,b,c,d Partial light sources [0030] [0030] 4 , 4 a,b,c,d Collecting optical systems [0031] [0031] 5 a,b,c,d Partial beams [0032] [0032] 6 Object plane of 1 [0033] [0033] 7 Prism [0034] [0034] 8 a,b Reflection surfaces [0035] [0035] 9 Collecting optical system [0036] [0036] 10 Laser diode [0037] [0037] 11 Cylindrical lens [0038] [0038] 12 a,b Plates [0039] [0039] 13 Polarization cube
In order to improve target illumination a light emitter comprises several partial light sources ( 3 a , 3 b , 3 c , 3 d ), the partial beams ( 5 a , 5 b , 5 c , 5 d ) of which are collected by means of a beam collector optic ( 2 ) and directed to the aperture of a collimator ( 1 ). The beam collector optic ( 2 ) comprises two half-mirrored sheets ( 12 a , 12 b ), which each direct two similarly polarised partial beams ( 5 a, b; 5 c, d ) side by side onto a polarisation cube ( 13 ), where the pairs of partial beams which are polarised perpendicular and orthogonal to each other are overlaid.
6
BACKGROUND OF THE INVENTION This application is a continuation of application Ser. No. 06/083,034, filed Oct. 9, 1979, now abandoned. The problem of maintaining engine manifold cooling water at a temperature below boiling has established the need for a temperature sensitive circuitry to control cooling fans mounted on a locomotive. Various types of automatic control circuits for controlling fans to provide temperature regulation are known in the prior art. One such system is disclosed in U.S. Pat. No. 3,332,621 (Automatic Control Means) which discloses a cam operated system for selectively closing the electrical contacts of associated motors to drive various fans in accordance with the desired temperature regulation. SUMMARY OF THE INVENTION The present invention provides improved control circuitry for controlling and regulating the operation of multiple fans for providing cooling air flow in an associated engine. More specifically, the present invention is directed to a solid-state multistage temperature controller. The circuitry of the present invention includes a thermistor sensor which is a variable resistor device which provides improved operational accuracy of the controller circuitry. The variable resistor device enables the temperature set points of the controller to be easily adjusted by varying the resistance of the resistor device by interchanging thermistors or by changing the thick film resistor pack. Circuitry is included which detects and displays an open or shorted thermistor probe. The present invention also provides a selective time delay which prevents two fans from starting simultaneously. The delay may be by-passed in the event of fast temperature cycling. Current limiting or fold-back circuitry protects the control circuitry from damage for a time period limited to about thirty minutes upon the occurrence of a total or partial short. The foregoing features and advantages of the present invention will be apparent from the following more particular description of the invention. The accompanying drawings listed hereinbelow are useful in explaining the invention wherein: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of the inventive circuitry and includes a functional description of the various portions of the circuitry; FIG. 2 is a schematic diagram of the inventive circuitry; FIG. 3 is a schematic diagram of an embodiment of an output stage including fold-back circuitry of the invention; and, FIG. 4 is a schematic diagram of a current limiting circuitry of the invention. DESCRIPTION OF THE INVENTION As alluded to above, the requirement that engine manifold cooling water be maintained at a temperature below boiling has established the need for a multistage temperature sensitive circuitry to sequentially control the various cooling fans mounted on a locomotive. The present invention provides sensing and control circuitry including a thermistor sensing element or probe immersed in the coolant to provide a solid-state temperature control circuitry with an electrical signal proportional to the coolant temperature. When the coolant reaches a predetermined design temperature, the inventive circuitry will enable the first of the cooling fans; subsequent fans are enabled as coolant temperature increases. To minimize loading due to motor starting currents, time delay circuitry is used to sequence the operation of the cooling fans. In the event of a rapid temperature rise, the time delay of the circuitry will be adjusted to permit the fan motors to be enabled more rapidly. If all available fans are insufficient for providing adequate cooling, an emergency throttling system is activated to reduce engine speed and thus decrease the cooling temperature. Referring to both FIG. 1 and FIG. 2, power for the multistage temperature controller circuitry 11 is provided from a 74 VDC bus supplied from the locomotive power generating facilities. Voltage reversal protection, such as might occur due such as to an installation error, is provided by a diode 14 connected in series between the +74 VDC supply and the controller circuitry. A varistor 15 connected across the power leads 22A and 22B provides protection from unwanted transients for the semi-conductors and for the integrated circuit (IC) chips in the circuit 11. Varistor 15 is connected in parallel with a diode 16 (see right upper portion of FIG. 2), such that voltage spikes greater than the breakdown voltage of the diode 16 will be clamped by the varistor 15 while negative spikes will be limited to the forward bias voltage of the diode 16. A zener diode 17 provides +10 VDC limit supply used for operation of the logic and linear integrated circuits of FIG. 1. A resistor 18, connected in series with zener diode 17, assures that the input current from the +74 VDC supply is essentially constant. A capacitor 19 connected in parallel with the zener diode 17 provides transient protection for the low voltage supply. The voltage across the zener diode 17 is coupled across a resistive bridge network comprising eight resistors generally labeled 21. The junction of a thermistor sensor 23 and resistors 13 is connected to provide one input to each of the operational amplifiers 25A-25D functioning as comparators. The other input to each of the comparators 25A-25D is a selected voltage reference level obtained from the resistive bridge network. The changing resistance of the thermistor 23 determines the voltage input to the inverting terminal of each of the comparators 25A-25D (note the terminal points generally labeled 24); and, this varying voltage across the thermistor 23 determines the switching temperatures of the comparators 25A-25D. A resistor 26 and push-button 27 in parallel with the thermistor 23 provides a push-to-test function. The value of the resistor 26 is chosen so that when the push-button 27 is depressed, the parallel combination of the resistor 26 and thermistor 23 will be a low resistance which will simulate a high coolant temperature. Therefore, with the push-button 27 depressed, all output stages of the controller of FIG. 1 should operate indicating the operating condition of the controller circuitry. A capacitor 31 connected in parallel with the thermistor 23 and push-to-test button 27 dampens unwanted transients. As mentioned above, comparator section 25 of the temperature controller utilizes operational amplifiers 25A, 25B, 25C and 25D functioning as comparators. The voltage across the thermistor 23 is coupled from terminal, generally labeled 24, to provide the inverting (-) input for each of the comparators, while the resistive bridge network 21 establishes the reference voltage inputs to the non-inverting (+) terminals of the comparators 25. The reference voltage inputs are compared with the voltage across the thermistor 23 and determine the temperature at which the respective cooling fans will operate. Positive feedback through respective resistors, generally labeled 38, between the output of each of the comparators 25A-25D to their corresponding non-inverting (+) input provides the required hysteresis. As an example of operation of the comparator circuitry, a temperature of 174 degrees is required for the first stage, comparator 25A, output to saturate or go logically high (Ta cooling fans are turned ON). Each successive comparator 25B, 25C and 25D saturates as the temperature of the coolant reaches the setpoint determined by the resistor network 21. When the thermistor 23 voltage starts to increase as the coolant temperature decreases, the comparators 25A-25D will be turned OFF (fans are turned ON) in a reverse sequence. A time delay circuit 40 is provided to inhibit any two fans from being started simultaneously. The delay circuit 40 consists of a resistor 43 and capacitor 44 network, which has a long time constant; and, an inverter generally labeled 42. The discharge time constant is reduced by using a diode 46, and a resistor 47 having a low resistance, in the discharge path for capacitor 44 so that there is little or no delay when switching off. The operation of the time delay circuit can be considered as follows. When Ta is engaged, a low voltage is fed back from terminal 39, through resistor 41 and inverted by inverter 42 to provide a selected voltage input to the resistor 43 and capacitor 44 network. The capacitor 44 charges to a high level after approximately thirty seconds and provides a logic HIGH level to one input of the AND gate 45. As the temperature rises to the pick-up point of Tb, the other input to the AND gate 45 goes high and the Tb stage is engaged. Conversely, when the temperature drops below the drop out point of Tb, a logic LOW level is applied to one input of the AND gate 45 and Tb is disabled. Since Ta remains engaged, the state of the resistor 44 and capacitor 43 network is unchanged making it possible for Tb to be re-activated without the thirty second delay when the temperature again rises. The foregoing permits the delay circuit to compensate for fast temperature cycling through the turn ON levels of the various fans; and, thus, enable a fan which has been turned OFF to be turned ON without a delay if the temperature first decreases then again starts to rise. The outputs Ta, Tb, Tc, ETS (emergency throttling system) from the comparator circuits 25A-25D become the inputs to AND gates generally labeled 45. The AND gates 45 for Ta and ETS function to establish the needed logic level outputs for Ta and ETS, while the AND gates 45 in the circuits for Tb and Tc insure that the fans will operate in sequence. The control circuitry has been so designed that a low logic level is necessary to activate the power output stages. Since the comparator circuitry provides high level output signals to indicate that cooling fans should be ON, NAND gates, generally labeled 48, are provided to give a low level output for normal operation. Referring now to FIG. 3, the outputs from the NAND gates 48 provide the logic inputs to the power output stages through buffer transistor 49. For high level signals to the output stages, the buffer transistor 49 will conduct considerable collector current and will hold the power transistors 50 and 51 off because of the limited base drive to transistor 50. For low level inputs, the buffer transistor 49 will not be conducting, and the power transistors 50 and 51 will consequently be ON causing the output circuit of FIG. 3 to provide an output. The two power transistors 50 and 51 are connected as a Darlington pair configuration to provide maximum output current with the collector-emitter voltage of transistor 51 being at a minimum, thereby increasing efficiency and minimizing heat dissipation problems. A metal oxide varistor 53 guards against transients caused by the inductive load of the motor fans. An important feature of the invention is the current limiting or "fold-back" circuitry, shown in FIG. 3, and which will now be explained. During normal operation, with the transistor 49 OFF and transistor 51 saturated, transistor 54 will provide current to resistor 55 (a 200 ohm resistor), thereby holding the voltage at the emitter of transistor 52 at a constant level. The emitter of transistor 51 will be at a voltage greater than the voltage at the emitter of transistor 52 establishing a certain amount of current through resistor 56 (a 7.5 ohm resistor). Transistor 52 will be ON, but the base voltage of the transistor 50 will be high so that transistor 52 collector current will be low and the circuit will operate normally. Note that the collector of transistor 52 is coupled back to the base of transistor 50. Upon the occurrence of a total or partial short, transistor 54 will be turned off thereby reducing the voltage across resistor 55. In this latter condition, the transistor 51 emitter current establishes the voltage across resistor 56 and drives transistor 52 to saturation. The collector current of transistor 52 (coupled through lead 59 to the collector of transistor 49) will reduce the base drive to the transistor 50 and bring the power transistors 50 and 51 out of saturation. The collector emitter voltage of the transistor 51 will rise and the collector current will decrease thereby limiting the output current on lead 61. The fold-back circuitry will protect the controller from destruction for a short time period limited to approximately fifteen minutes. The temperature rise of the power transistors will destroy the controller circuitry if subjected to longer periods of shorted conditions. Refer now to FIG. 4 which shows an alternative embodiment of the emergency throttling system, and designated as ETS2. With the exception of the ETS2, all power output stages are identical. The difference in ETS2 is shown in FIG. 4, and that difference being that power transistor 51 is not used in FIG. 4, and only power transistor 50 is used because of a lower output current requirement. Also, conventional current limiting with an NPN transistor 52 is used for the ETS2 output stage. Refer now to FIGS. 1 and 2 with reference to the shorted sensor indicator. Should thermistor 23 short, the voltage across thermistor 23 goes to zero, and this voltage is coupled through lead 61 and resistor 62 to turn OFF transistor 63 and cause NPN transistor 64 to turn ON to cause current to flow through and light LED 65 to indicate a short condition. An open sensor indicator 29 detects and alerts the user to an open thermistor 23 probe. An operational amplifier (op-amp) 32 circuit is used as a voltage comparator with the output voltage of thermistor 23 coupled to amplifier 32 as the inverting input (-) and a voltage divider network made up of discrete resistors 17a and 19b providing the non-inverting (+) input provides the necessary hysteresis. The amplifier 32 output becomes the input to an electronic "switch" comprising transistors 28 and 29 which drive a light emitting diode (LED) 30 indicator. During normal operating conditions, the voltage across the thermistor 23 will be relatively low and so the inverting input to the op-amp 32 will be at a low potential. Since the input to the non-inverting (+) terminal is fixed at a voltage chosen such that only in the event of an open probe will the op-amp 32 change stages, the output will be high. The transistor 28 will be saturated while transistor 29 is held off since the collector emitter voltage of transistor 28 is insufficient to forward bias the base emitter junction of transistor 29. Therefore, no current flows through the LED 30, indicating that the probe is not opened. Should the thermistor 23 probe be opened, the voltage at the inverting (-) input of op-amp 32 approaches +10 volts which is sufficient to drive the op-amp 32 low [the voltage at the inverting (-) input is greater than voltage at the non-inverting (+) input]. This in turn holds transistor 28 off while transistor 29 is saturated and drive and light the LED 30, thereby indicating an open probe. Because of inherent offset voltages at the input to the op-amp 32 and device tolerances, the open probe indicator will falsely show a probe failure when the thermistor is exposed to temperatures below 0 degrees Fahrenheit. Also, once the op-amp 32 is driven low, the thermistor ambient must reach approximately 20 degrees Fahrenheit before the op-amp 32 is driven high extinguishing the LED. However, such false indications present no problem since the thermistor ambient will exceed 20 degrees Fahrenheit whenever the locomotive is operating. While the 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 details may be made therein without departing from the spirit and scope of the invention.
A solid-state, multistage temperature controller for automatically controlling the operation of fans to maintain the temperature of an associated engine within preselected limits.
6
FIELD OF THE INVENTION The present invention is directed to a class of compounds that are made by neutralizing the amino group in an amphoteric surfactant with the carboxylic acid group in an alkoxylated fatty alcohol compound. The complex has (a) lower irritation, (b) better foaming properties and (c) improved substantivity to a variety of substrates. BACKGROUND OF THE INVENTION The present invention relates to specific salts of amphoteric surfactants and carboxy fatty compounds. The compounds have unique properties including high foam, detergency and most importantly low irritation to the eye and skin. This makes the compounds of the present invention particularly well suited for personal care applications. Additionally, the compounds of the present invention are useful in industrial applications where detergency and substantivity are required. One particular application is in metal cleaning and corrosion inhibition. The compounds of the present invention provide both detergency and corrosion inhibition when applied to metal surfaces. Amphoteric surfactants have been known for many years. The amphoteric compounds useful in the preparation of the compounds of the present invention are amino propronates. U.S. Pat. No. 3,417,136 to Hovoden describes the basic technology used to make amphoteric surfactants of the class which is useful for the preparation of the complexes of the present invention. Silicone carboxy complexes are disclosed in U.S. Pat. No. 5,739,371 issued April 1998 to O'Lenick, incorporated herein by reference. That specific patent disclosed that silicone polymers were needed to observe the beneficial effects observed. We have now surprisingly observed that the same effect is obtained using fatty alcohol carboxylates in place of silicone carboxylates. This has very far reaching impact upon cost and formulation latitude in personal care products. SUMMARY OF THE INVENTION The compounds of the present invention are salts of an amphoteric and an alkoxylated alkyl carboxylate. The preparation of the specific salt compounds of the present invention results in properties heretofore unattainable. Specifically, the fatty amphoteric compounds of the present invention are good detergents, but are somewhat irritating to the skin and eyes. This irritation results in a defatting of the skin and an unacceptable feel on the skin. The alkoxylated alkyl carboxylate per se is neither a good detergent nor very mild to the skin. Surprisingly, both together in a salt of the present invention, the compounds of the present invention are very mild to skin and eye, and possess outstanding detergency. This combination of properties make compounds of the present invention applicable many personal care applications, where the cost of silicone is prohibitive. Another very useful application for the salts of the present invention is in two in one shampoos. If one makes a complex of a standard fatty quaternary compound and a standard fatty anionic surfactant, the resulting salt is water insoluble and of very little usefulness in either cleaning or conditioning hair. The salts of the present invention are water soluble and unexpectedly provide both detergency and conditioning to the hair in a single application. OBJECT OF THE INVENTION It is the object of the present invention to provide a series of amphoteric/carboxy salts. These compounds have an outstanding combination of properties making them useful in personal care, and industrial applications. Another aspect of the present invention is a process for using the compounds of the present invention in cleaning and conditioning hair with the application of a single compound. DETAILED DESCRIPTION OF THE INVENTION The amphoteric surfactants from which the compounds of the present invention are based have the following structure: R 3 —N—(CH 2 CH 2 C(O)—O − M + ) 2 R 3 is selected from the group selected from CH 3 —(CH 2 )d— and CH 3 —(CH 2 ) e —O—; d is an integer ranging from 7 to 19; e is an integer ranging from 7 to 19; M is selected from Na, K, and Li. The nitrogen group in the molecule is a tertiary amine and can be neutralized with a carboxylic acid. Such an acid is the alkoxylated acid useful in the preparation of the compounds of the current invention. The reaction is a neutralization reaction and can be explained by the following reaction sequence: R 3 —N—(CH 2 CH 2 C(O)—O − M + ) 2 +RC(O)OH An organic Base An Organic Acid R 3 -N+(H)-(CH 2 CH 2 C(O)-O- M+) 2 RC(O)O An organic salt The compounds of the present invention are salts which conform to the following structure:  A − B + wherein A is R 1 —O—C(O)—R 2 —C(O)O R 1 is CH 3 —(CH 2 ) n —O—(CH 2 CH 2 O) a —(CH 2 CH(CH 3 )O) b —(CH 2 CH 2 O) c —; n is an integers ranging from 7 to 21; a and c are integers independently ranging from 0 to 20, with the proviso that a+b be greater than 5; b is an integer ranging from 0 to 20; R 2 is selected from the group consisting of —CH 2 —CH 2 —, —CH═CH—, and and B is R3—N + (H)—(CH 2 CH 2 C(O)O − M + ) 2 R 3 is selected from the group selected from CH 3 —(CH 2 ) d — and CH 3 —(CH 2 ) e —O—; d is an integer ranging from 7 to 19; e is an integer ranging from 7 to 19: M is selected from Na, K, and Li. Preferred Embodiments In a preferred embodiment R3 is CH 3 —(CH 2 ) d —. In another preferred embodiment R3 is CH 3 —(CH 2 ) e —O—. In a preferred embodiment d is 7. In a preferred embodiment d is 9. In a preferred embodiment d is 11. In a preferred embodiment d is 13. In a preferred embodiment d is 15. In a preferred embodiment d is 17. In a preferred embodiment d is 19. In a preferred embodiment e is 7. In a preferred embodiment e is 9. In a preferred embodiment e is 11. In a preferred embodiment e is 13. In a preferred embodiment e is 15. In a preferred embodiment e is 17. In a preferred embodiment e is 19. EXAMPLES OF REACTANTS Anhydrides The various anhydrides listed are all items of commerce and are prepared by methods known to those skilled in the art. Reactant Example I (Succinic Anhydride) Reactant Example II ( Maleic Anhydride) Reactant Example III (Phthalic Anhydride) Alcohol Alkoxy Carboxylate The reaction sequence is illustrated by the reaction with succinic anhydride: Raw Materials Alkoxylated alcohols suitable for the preparation of the compounds of the present invention are commercially available from Siltech Corporation in Toronto Ontario Canada. R 1 —O—C(O)—R 2 —C(O)OH Example n a b c 1  8  0 0  5 2 10  0 1 12 3 12 20 10  20 4 14  3 1  3 5 16 20 20  20 6 18 12 0  0 7 20 12 1  1 8 22  5 0  5 General Reaction Conditions Into a suitable round bottom, three neck flask equipped with a thermometer and a nitrogen sparge is added the specified number of grams of the specified alcohol alkoxylate compound and the specified number of grams of the specified anhydride. The reaction mass is blanketed with nitrogen, and heated to 80 and 110 C. under the inert nitrogen blanket. Within four to five hours the theoretical acid value is obtained. The product is a clear liquid and is used without additional purification. Examples 9-18 Succinic Derivatives Into a suitable round bottom, three neck flask equipped with a thermometer and a nitrogen sparge is added the specified number of grams of the specified alcohol alkoxylate (examples 1—8) compound and the 100.0 grams of succinic anhydride. The reaction mass is blanketed with nitrogen, and heated to 80 and 110 C. under the inert nitrogen blanket. Within four to five hours the theoretical acid value is obtained. The product is a clear liquid and is used without addition purification. Alcohol Alkoxylate Example Example Grams  9 1 391.0 10 2 742.0 11 3 2533.0 12 4 447.0 13 5 3179.0 14 6 795.0 15 7 926.0 16 8 763.0 Examples 17-24 Maleic Derivatives Into a suitable round bottom, three neck flask equipped with a thermometer and a nitrogen sparge is added the specified number of grams of the specified alcohol alkoxylate (examples 1-8) compound and the 98.0 grams of maleic anhydride. The reaction mass is blanketed with nitrogen, and heated to 80 and 110 C. under the inert nitrogen blanket. Within four to five hours the theoretical acid value is obtained. The product is a clear liquid and is used without additional purification. Alcohol Alkoxylate Example Example Grams 17 1 391.0 18 2 742.0 19 3 2533.0 20 4 447.0 21 5 3179.0 22 6 795.0 23 7 926.0 24 8 763.0 Examples 25-32 Phthalic Derivatives Into a suitable round bottom, three neck flask equipped with a thermometer and a nitrogen sparge is added the specified number of grams of the specified alcohol alkoxylate (examples 1-8) compound and the 146.0 grams of phthalic anhydride. The reaction mass is blanketed with nitrogen, and heated to 80 and 110 C. under the inert nitrogen blanket. Within four to five hours the theoretical acid value is obtained. The product is a clear liquid and is used without additional purification. Alcohol Alkoxylate Example Example Grams 25 1 391.0 26 2 742.0 27 3 2533.0 28 4 447.0 29 5 3179.0 30 6 795.0 31 7 926.0 32 8 763.0 Amphoteric Surfactants R 3 —N—(CH 2 CH 2 C(O)—O − M + ) 2 R 3 is selected from the group selected from CH 3 —(CH 2 ) d — and CH 3 —(CH 2 ) e —O—; M is selected from Na, K, and Li; d is an integer ranging from 7 to 19; e is an integer ranging from 7 to 19; Class 1 (Alkyl Amphoteric) R 3 is CH 3 —(CH 2 ) d — The amphoteric surfactants of this class are commercially available from a variety of sources including Henkel Corporation. These products are available at a variety of actives. Therefore all were adjusted to 30% actives prior to use. Consequently, the grams listed in the examples for these materials is based upon 30% actives. Example M d 33 Na  7 34 K  9 35 Na 11 36 Li 13 37 Na 15 38 K 17 39 Na 19 Class 2 (Alkyl Ether Amphoteric) Compounds of this class are commercially available from a variety of sources, most importantly Tomah Products of Milton Wis. These products are available at a variety of actives. Therefore all were adjusted to 30% actives consequently, the grams listed in the examples materials is based upon 30% actives. R 3 is CH 3 —(CH 2 ) 3 —O—; Example M e 40 Na  7 41 K  9 42 Na 11 43 Li 13 44 Na 15 45 K 17 46 Na 19 Examples The compounds of the present invention are prepared by the mixing of the amphoteric surfactant and the carboxy compounds, preferably in aqueous solution, resulting in the neutralization of the compounds and preparation of the salts of the current invention. Example 47 1136.0 grams amphoteric compound at 30% Active (example 33) is added to a suitable vessel. Next 391.0 the specified carboxy (example 9) is added under good agitation. Water is then added to adjust the solids to 40%. The resulting salt is ready to use without additional purification. The compounds can be prepared in aqueous solution if desired by addition of water. Preferred concentrations are between 50% and 30% amphoteric solids by weight. Note: In the below table Gms. is grams Examples 48-79 Carboxy Amphoteric Compound Compound Example Example Grams Example Grams 48 11 2533.0 37 1510.0 50 12 447.0 38 1710.2 51 13 3179.0 39 1697.0 52 14 795.0 40 1190.0 53 15 926.0 41 1390.0 54 16 763.0 42 1270.0 55 17 391.0 43 1470.0 56 18 742.0 44 1563.0 57 19 2533.0 45 1656.0 58 20 447.0 46 1750.0 59 21 3179.0 33 1136.6 60 22 795.0 34 1336.2 61 23 926.0 35 1323.0 62 24 763.0 36 1370.0 63 25 391.0 33 1136.6 64 26 742.0 34 1336.0 65 27 2533.0 35 1323.0 66 28 447.0 36 1310.0 67 29 3179.0 37 1510.0 68 30 795.0 38 1710.2 69 31 926.0 39 1697.0 70 32 763.0 40 1190.0 71 10 742.0 36 1310.0 72  9 391.0 36 1310.0 Applications Examples The compounds of the present invention are low irritation surface active agents which exhibit good detergency and foam properties. This combination of properties makes the compounds useful in personal care applications. The following data illustrates the desirable properties of the salts which are lacking in either component alone. Amphoteric Carboxy Complex Example 33 Example 1 Ex 47 Eye Irritation Moderate Mild Mild Detergency Good Poor Good Foam Good Poor Good
The present invention is directed to a class of compounds that are made by neutralizing the amino group in an amphoteric surfactant with the carboxylic acid group. The complex has (a) lower irritation, (b) better foaming properties and (c) improved substantivity to a variety of substrates.
2
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Application Ser. No. 61/838,952 filed on Jun. 25, 2014, the contents of which are hereby incorporated in their entirety. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not Applicable. NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT [0003] Not Applicable REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC AND INCORPORATION-BY-REFERENCE OF THE MATERIAL [0004] Not Applicable. BACKGROUND OF THE INVENTION [0005] 1. Field of the Invention [0006] The present invention relates to a substrate for manufacturing customizable interlocked web products. More particularly, the invention relates to an apparatus and method for making bracelets and other products which are composed of elastic bands and may be customized by being interlinked in different patterns and by attaching charms to them. [0007] 2. Background Information [0008] Ornamental bands such as bracelets, anklets and necklaces made of interlinked elastic materials such as rubber bands and other related materials are popular accessories that people wear to represent school spirit, group associations and other symbolic forms of expressions. Bands can be worn on the arms and also on other areas of the body such as on the ankles. These bands are very difficult to manufacture by hand, as skill in the art and a great quantity of time is required, which many people do not have. [0009] Finding ready-made elastic jewelry products customized to an individual's needs can be very difficult, and also very expensive, as the need to purchase more jewelry increases. [0010] It is therefore desirable to provide a device which can easilyist any person wishing to sevl lined bands to form a braceletther device. [0011] It is also desirable to provide an easy method of creating such interlinked bands performable by anyone regardless of knowledge or skill [0012] It is also desirable to provide a device which allows an easy method of creating customizable elastic jewelry products. BRIEF SUMMARY OF THE INVENTION [0013] The principles of the invention provide a device and method which allows the end user to conveniently cross link elastic materials such as rubber bands by providing an easy to use pin wheel guiding platform, and an interlocking utensil. [0014] An object of the invention is to provide an easy method of making a customizable elastic jewelry products and one that is more economical for the average end user. [0015] Another object of the invention is to provide a new and unique type of jewelry making device which allows the user to make customizable products which may not be available on the market. [0016] In one embodiment, a platform has a plurality of substrate stations. Each substrate stations have a pair of upwardly protruding, cylindrical stems. The stems each have a bulbous cap that may protrude more in one direction, such as away from each stem. The plurality of substrate stations may be arranged in one or more rows, and may be numbered and/or provided a beginning and end point for each row. The stems may protrude from a pedestal, or other base-like structure at the bottom of the substrate station. [0017] In use, elastic bands may be placed on each pin pair of each substrate station and subsequently interlinked with one another to produce a bracelet, necklace or other woven product. A utensil may be used to assist in interlinking the bands. The bands may be interlinked in a variety of different patterns. Charms or other objects may also be used to ornament the web product. [0018] In another embodiment, a platform for weaving interlinking elastic bands comprises a platform having a top surface and a plurality of stations on the top surface. The stations are aligned into one or more rows. [0019] Each of the stations comprises a pedestal, two stems extending upward from the pedestal, each of the stems having a crown. [0020] In one embodiment, the stations are removably attached to the platform. The platform may further comprise one or more storage wells, and/or a clip for holding a weaving utensil and a weaving utensil. [0021] In another embodiment, the platform is circular. The crowns of the stems may be spherical or oblong. If they are oblong, they may face away from each other and/or be perpendicular to the direction of the rows. [0022] In another embodiment, the stations are removably attached to the platform and the platform may include one or more storage wells. [0023] Also disclosed is a method for weaving interlinking bands comprising the steps of a) stretching an elastic band between two or more stems of two or more stations of a platform having a plurality of stations aligned into one or more rows such that tension created by the stretching holds the band in place suspended between the two or more stems, b) stretching another elastic band between two or more stems of two or more stations of a platform having a plurality of stations aligned into one or more rows such that tension created by the stretching holds the band in place suspended between the two or more stems, c) pulling a portion of one of the elastic bands through the elastic band by means of a weaving utensil, d) attaching the portion of the elastic band pulled through another elastic band to at least one stem such that tension caused by stretching the elastic band holds the portion in place about the at least one stem; and repeating steps a-d to provide a plurality of interwoven elastic bands. [0024] The method for weaving interlinking elastic bands may use stems includes a spherical or oblong crowns, which may be perpendicular to the rows. [0025] These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. BRIEF DESCRIPTION OF THE DRAWINGS [0026] A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein: [0027] FIG. 1 is a perspective view of a circular platform for weaving interlinking elastic bands in accordance with the principles of the invention; [0028] FIG. 2 is a perspective view of a station in accordance with the principles of the invention; [0029] FIG. 3 is top view of the circular platform for weaving interlinking bands in accordance with the principles of the invention; [0030] FIG. 4 is a side view of a removably attachable station use with removable stations in accordance with the principles of the invention; [0031] FIG. 5 is an alternative top view of a circular platform having a plurality of sockets for removable attachment of stations in accordance with the principles of the invention; [0032] FIG. 6 is a cross-sectional side view of a circular platform having a plurality of sockets for removable attachment of stations in accordance with the principles of the invention; [0033] FIG. 7 is an enlarged view of a portion of a cross-sectional side view of a circular platform having a plurality of sockets for removable attachment of stations in accordance with the principles of the invention. DETAILED DESCRIPTION [0034] 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 to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. [0035] FIG. 1 shows a circular platform for weaving interlinking bands 10 in accordance with the principles of the invention. Platform 10 is comprised of a base 12 in the shape of a flattened cylinder. The base 12 has a top surface. The top surface 14 may include two storage wells 20 that may be used to store elastic bands or other materials. Top surface 14 may also include a clip 22 for securing a weaving utensil 18 to the top surface 14 when not in use. In this embodiment, the weaving utensil 18 may be elongate having a handle 19 on one end and a weaving hook 17 on the opposite end. [0036] A large portion of top surface 14 may be covered by a plurality of stations 16 . Each station 16 may be designed to accommodate one or more elastic bands during the weaving process. The stations 16 may be arranged in one or more rows. [0037] FIG. 2 is an enlarged view of a station 16 . Stations 16 may have a pedestal 30 serving as a base for the station 16 . Two stems 32 may extend upward from the pedestal 30 . Each of stems 32 may have a crown 34 at the top. Each crown 34 may be spherical, oblong, parallelepiped or other shape. The crown may include a distal end 36 extending at least partially perpendicular to the stem 32 . In this embodiment, the distal ends 36 of the oblong “egg-shaped” crowns 34 extend away from each other, may be substantially perpendicular to the stems 32 and may have rounded edges. In other embodiments, it may be desirable for the distal ends 36 of the crowns 34 to extend in the same direction, perpendicular to each other, or at an acute or obtuse angle relative to each other. [0038] Stems 32 may be substantially cylindrical and rigid. It is generally desirable for the stems 32 to be rigid in order to securely retain elastic bands in a semi-extended form, and held in place by tension resulting from the elastic bands being stretched over two or more stems. In some embodiments, it may not be desirable for stems 32 to be completely rigid. It may also be desirable for stems 32 to have an oval or polygonal cross-section instead of being cylindrical. Similarly, in this embodiment, pedestal 30 is cylindrical. It may be desirable for pedestal 30 to be more prismatic or rectangular. Optionally, it may be desirable for the pedestal 30 to be rounded, or have a hemispherical shape. This embodiment of a station 16 has bilateral symmetry. Stations may optionally have other types of symmetry or none at all. [0039] FIG. 3 shows a top view of the circular platform 10 . It may be seen that top surface 14 is substantially bilaterally symmetric. As a result, wells 20 may be symmetrical. The stations 16 may be generally aligned in rows as shown here. An outer row 40 , central row 42 and inner row 40 . are substantially parallel to each other. The top surface 14 may include numbering in order to designate each individual substrate station 16 for ease of use. [0040] FIG. 4 shows a side view of a removably attachable station 50 , designed as a unitary manufactured piece for integration with a separately manufactured platform shown in FIGS. 5-7 . Removably attachable station 50 includes a pedestal 52 and two stems 54 . As with substrate station 16 in FIGS. 1-3 , pedestal 52 is a flattened cylinder. Stems 54 are topped by crowns 56 , each having an oblong shape. Station 50 includes a bottom portion 60 having two downwardly protruding fingers 62 each having a tab 64 that snaps into place when the station 50 is attached to a platform. [0041] FIG. 5 shows a circular platform 70 having a plurality of substrate station sockets 76 arranged in three rows on the top surface 74 of platform 70 . Storage wells 78 may be used to hold objects while clamp 80 may be used to hold a weaving utensil (not shown). A station 52 , as shown in FIG. 4 may be snapped into each of the station sockets 76 . FIG. 6 shows a cross-sectional view of platform 70 along axis A and FIG. 7 shows an enlarged view of a portion of FIG. 6 . In both FIGS. 6 and 7 it may be seen that wells 78 and sockets 76 are cavities within platform 70 . By providing removable attachment of stations into sockets on a platform, the weaving platform in accordance with the principles of the invention allows simple repair and/or replacement of stations. Because the stems are relatively thin and are exposed to forces imparted by elastic bands stretched over them, they may be prone to breaking [0042] The platforms in the embodiments are circular having three rows. Optionally, the platforms may be rectangular, ovoid, or any other shape and may have only one row, or may have more than three rows running parallel. [0043] In use, elastic bands are stretched over two or more stems, either on the same station or on neighboring stations. A weaving utensil may then be used to pull a portion of one of the elastic bands through another band. The stretched portion may then be attached to another stem. In this manner, a Brunnion link is formed, connecting the two bands. This process is continued for many elastic bands over many stems to form a long chain of elastic bands all interconnected by means of Brunnion links. [0044] Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated. [0045] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
A platform for linking elastic bands together to form bracelets, anklets, necklaces and jewelry products has a circular platform having a plurality of substrate stations for retaining elastic bands in a semistretched configuration. An interlinking utensil allows a user to make cross-linked jewelry products which can be worn around a wrist or other area of the body. The substrate stations may be aligned in one or more rows.
3
This is a continuation of Ser. No. 656,489, filed Feb. 9, 1976, now abandoned. BACKGROUND OF THE INVENTION This invention relates to a tool for the installation of items that require tensioning and more particularly to a tool for the installation of fasteners such as cable ties. Cable tie fasteners are commonly installed, for example, by wrapping their straps around groups of articles and then threading the straps through locking heads. The installation is completed by pulling on the free ends of the straps until the articles are securely bundled. To achieve a suitable installation it is desirable to use a tool which grips and tensions the free end of the strap. The free end is then severed in the vicinity of the head when a specified level of tensioning has been reached. Installation tools in common use contain a trigger actuated mechanism that tensions the strap to a predetermined level and actuates a cutter to sever the strap. Such tools commonly require the application of a relatively high operating force to the trigger through an appreciable interval. In some cases there is a considerable span between the hand grip of the gun and the trigger. The result is that the tools can be difficult to operate and can cause undue user fatigue. Another characteristic of existing installation tools is that the cutoff mechanism produces a significant shock effect. At the instant of severing there is a pronounced snap which, at high tension levels, can even sting the user. In addition there is the objectionable tendency for the severed end of the strap to be ejected from the tool towards the user. Another objection is the tension level adjusting mechanism is often unreliable and difficult to operate. Accordingly, it is an object of the invention to reduce the shock effect associated with the severing of items under tension. A related object is to reduce the shock effect associated with the severing of tensioned fasteners. A further related object is to reduce the shock effect associated with the severing of tensioned cable tie straps. Another object of the invention is to achieve an installation tool in which an item may be tensioned and severed using a reduced amount of trigger force. A related object is to achieve the tensioning and severing of an item using a trigger which has a comparatively short operating span. A further object of the invention is to provide an accurate and easily adjustable tensioning level for an installation tool. Still another object is to avoid the objectionable tendency of items that are severed under tension to fly back and strike the operator. Illustrative installation tools of the prior art are disclosed in U.S. Pat. Nos. 3,735,784; 3,712,346; 3,661,187; 3,433,275; 3,344,815; 3,332,454; 3,284,076; 3,173,456; 3,169,560 (U.S. Pat. No. Re. 26,492); 3,168,119; 3,154,114; 2,729,994; 2,882,934; and 2,175,478. SUMMARY OF THE INVENTION In accomplishing the foregoing and related objects the invention provides an installation tool in which a tensioning assemblage is driven through an intervening toggle linkage that is able to actuate a sever mechanism. The intervening linkage is prevented from collapsing until a certain level of tensioning is attained by the application of a countervailing force. In accordance with one aspect of the invention the toggle linkage is drawn through an internally pivoted actuator lever to reduce the amount of operator applied force. In accordance with another aspect of the invention the countervailing tension is applied by a compression cage. In accordance with a further aspect of the invention the tool uses an ejector spring to propel severed items away from the user. DESCRIPTION OF THE DRAWINGS Other aspects of the invention will become apparent after considering various illustrative embodiments, taken in conjunction with the drawings in which FIG. 1 is a perspective view of a tool in accordance with the invention being used in the installation of a cable tie; FIG. 2A is a perspective view of the tensioning and sever mechanisms in the installation tool of FIG. 1; FIG. 2B is a schematic representation of the tensioning and severing mechanisms of FIG. 2A during tensioning; FIG. 2C is a schematic representation of the tensioning and severing mechanism of FIG. 2A during severing; FIG. 3A is a perspective view of a compression spring cage for the adjustment of tension in accordance with the invention; FIG. 3B is a perspective view of the interior of the cage of FIG. 3A; FIG. 4A is a view of the installation tool of FIG. 1 with portions broken away to show the placement of constituents pictured in FIGS. 2A through 3B; FIG. 4B is an end view of the tool of FIG. 4A, and FIG. 4C is a top view of the tool of FIG. 4A. DETAILED DESCRIPTION Turning to the drawings, an installation tool 10 in accordance with the invention is formed by a split-cover housing 10h containing a tensioning assemblage 11 and a pivotted cutoff lever 12, which is visible through a viewing aperture of a cutter guard 12g and mounts a cutter blade 12b. As illustrated in FIG. 1, the tool 10 can be used to complete the installation of an item such as a cable tie 20. The strap portion 21 of the tie 20 is wrapped around articles that are to be bundled, for example the individual wires W of a cable C. A free end 22 of the tie 20 is inserted through the head 23 of the strap into the mouth of the tool 10 between gripper constituents 11p and 11a of the tensioning assemblage 11. When force F t is applied to a trigger 13 of the tool 10, it is transmitted through levers and linkages (not visible in FIG. 1) to the tensioning assemblage 11, causing the assemblage to be drawn towards the rear of the gun. This frees a pivotted and spring-loaded pawl 11p which rotates against the portion 22 of the strap and grips it with respect to a stud 11a. The initial rearward motion of the tensioning assemblage 11 caused by the force Ft tightens the portion 21 of the strap around the wires W of the cable C, with the head 23 of the cable tie 20 in close abutment with the tool 10. Further movement of the tensioning assemblage 11 increases the tension applied to the gripped portion 22 of the tie 20 until a predetermined tension level is reached. At that point, as explained below, the force transmitted to the tensioning assemblage 11 from the trigger 13 causes a collapse of the intervening linkage which acts upon the cutoff lever 12 and pivots it upwardly, bringing the blade 12b into sever position with respect to the gripped end portion 22 of the cable tie 20. In the typical operation of an installation tool the sever action produces a significant shock impact. However, in accordance with the invention this impact is significantly reduced because of the particular way in which the cutoff lever 12 is operated, as explained in conjunction with FIGS. 2A through 2C. A perspective view showing the relationship between the tensioning assemblage 11 and the cutoff lever 12 is given in FIG. 2A. The tensioning assemblage 11 is maintained in a normally forward position in the tool 10 by a compression spring 11c. The tensioning assemblage is connected to the trigger 13 through a set of actuator linkages including toggle linkages 14 and an internal actuator lever 15. When the trigger force F t is applied, it is transmitted through a trigger link 13 t to the actuator lever 15 which is pivotally mounted within the handle 16 of the tool 10. The upper portion of the actuator lever 15 is pivotally connected to the toggle linkages 14, which are, in turn, pivotally connected to the bar 11b of the tensioning assemblage 11. To maintain the toggle linkages 14 in position to transmit the trigger force F t , a countervailing force F c is applied to the midpoint 14m of the toggle through a toggle arm 14a.* When the tensioning force applied from the trigger 13 exceeds the countervailing force F c , the toggle collapses by pivoting with respect to both the actuator lever 15 and the tensioning bar 11b and engages a cam surface 12c of the cutoff lever 12. Since the operation of the cutoff lever takes place while the actuator lever is moving to the rear, there is, in effect, a cushioned impact of the collapsed toggle linkages 14 against the cutoff lever 12. It is believed that this cushioning limits the shock loading that is produced when the strap 22 is severed. In addition, an ejector spring 17, in the form of a leaf 17f with a curvature 17c extending into the mouth of the tool, is included to reduce any tendency for the severed end of the strap to be propelled toward the user. As the tensioning bar 11b is drawn towards the rear of the gun 10, the curved portion 17c of the ejector spring 17 tends to be flattened against the adjoining housing wall. When the pawl reaches a cam surface 11c (shown in FIGS. 1 and 2A), with the strap 22 under tension, the cam acts upon the pawl and partially releases it. In addition, as noted in FIG. 1, the housing 10h has a shield 10s that extends at the top of the gun to the vicinity of the ejector spring 17. Consequently when the strap is under tension, with the pawl 11p partially released and the spring 17 partially deflected, and the cutter blade 12b is operated to sever the strap, the severed portion tends to be propelled laterally out of the housing, instead of towards the user. The desired lateral propulsion is promoted by contributions from the shield 10s, the partial pawl release provided by the cam 11c and the ejector spring 17. This is by contrast with the tools of the prior art in which the pawl tends to be fully embedded in the leading portion of the strap at the moment of sever and there is no shield 10s, or ejector spring 17, so that when the strap is severed the accompanying release of tension tends to pivot the severed portion of the strap about the pawl and towards the user. A schematic representation of the tensioning and sever operation is illustrated in FIGS. 2B and 2C. Initially as shown in FIG. 2B the individual links of the toggle assemblage 14 are in alignment. For simplicity the toggle assemblage 14 in FIG. 2B is formed by the first link 14-1 that is pivotaly connected to the tensioning bar 11b and a second link 14-2 that is pivotally connected to the actuator lever 15. The actuator and sever links 14-1 and 14-2 are in turn pivotally joined. It is at this point of joinder 14m that the countervailing force F c is applied. To keep the countervailing force from driving the links 14-1 and 14-2 of the toggle assemblage out of alignment, the illustrative tensioning bar 11b in FIG. 2B includes an integral stop 11t. For the embodiment of FIG. 2A, the upward motion of the linkages is limited by the use of a slot 11s in the draw bar 11b as shown in FIG. 4A. The various ways of applying the countervailing force F c to the toggle assemblage 14 are discussed below. When the tension applied to the strap by the bar 11b exceeds the value of the countervailing force F c applied at the pivot center 14m of the toggle assemblage 14, that latter collapses as shown in FIG. 2C. This collapse brings a bearing surface 14b of the toggle into engagement with a cam surface 12b at the rear of the cutoff lever 12. Since the toggle assemblage 14 is formed by pivotally connected members, the force transmitted to the cutoff lever is composed of both horizontal and vertical components, by which a cushioned impact is applied to the cutoff lever 12, instead of a direct impact, so that impact shock loading is avoided. In addition, as is evident from FIG. 2B, the use of the trigger 13 in conjunction with the actuator lever 15 provides a mechanical advantage so that the amount of operator force applied to the toggle is considerably less than that needed with conventional installation tools. The use of the actuator lever 15 also permits the desired tensioning force to be applied over a relatively small arc of operation of the trigger 13. The countervailing force F c that is applied to the toggle 14 may be realized in a wide variety of ways. As shown in FIG. 2A the force F c is applied at the end of the toggle arm 14a. This upward component of countervailing thrust may be achieved by the use of a spring (not shown) which is hooked to the end of the linkage 14a. However, such a spring tends to be mechanically unreliable and in accordance with the invention the desired countervailing force F c can be realized using a compression spring cage 30 of the kind shown in FIGS. 3A and 3B. As indicated in FIG. 3A the end of the toggle linkage 14a is connected by a pivot pin 31p to an upper part 31 of the cage 30, which is slideably movable with respect to a lower part 32. Since the upper part 31 of the cage 30 applies the desired countervailing force F c to the toggle arm 14a and is therefore relatively immovable, since the arm initially cannot push the toggle links 14 beyond their co-liner position. As noted in conjunction with FIG. 2B the upward movement of the toggle linkage 14 is controlled by a stop member 11t which is an integral part of the tensioning bar 11b. To adjust the tension applied through the toggle arm 14a an adjusting member 32a is threaded into the bottom portion 32 of the cage 30 as shown in FIG. 3B by rotation of a tension control knob 33. This moves the lower portion 32 of the cage 30 of FIG. 3A upwardly with respect to the upper portion 31 and carries with it the indicator 32r that moves within a slot 31s of the upper portion 31 and simultaneously causes compression of the springs 32s which controls the countervailing force F c applied to the toggle assemblage. This arrangement achieves precise control over tension and a high degree of mechanical stability. A partial sectional view of the entire installation tool of FIG. 1 is shown in FIGS. 4A through 4C to indicate the relative positioning of the internal constituents of the tool, as well as the interrelations among those constituents. Thus in the tool 10 as shown in FIGS. 4A and 4B the toggle assemblage 14 is formed by four linkages (FIG. 4C) 14-1 through 14-4. The link 14-1 is seated on a hub 11h of the tensioning bar 11b. The link 14-1 is in turn pivotally connected to the arm 14a that extends to the compression cage 30. The arm 14a is connected to the lever 15 by a link 14-2, as well as by a further link 14-3. There is also pivotal connection between the hub 11h of the tensioning bar 11b and the arm 14a by a link 14-4. It is the latter link that limits the upward movement of the toggle assemblage due to the application of the compression force F c through the arm 14a. This is because the fourth linkage 14-4 (FIG. 4C) rides in a slot 11s (FIG. 4A) of the tensioning bar 11b. Initially with the full compression force F c applied to the arm 14a the individual links of the toggle assemblage are in alignment and the link 14-4 is seated in the upper part of the recess 11s. When the tension applied to the strap exceeds the countervailing force F c the toggle assemblage collapses as described previously and the link 14-4 moves out of the slot 11s to contact the cam surface 12c and operate the sever lever 12. Also indicated in FIGS. 4A and 4B is the placement of the cam 11c that provides partial release of the pawl 11p before sever. Details of the compression cage 30 are illustrated in FIGS. 4A and 4C. While various aspects of the invention have been set forth by the drawings and the specification, it is to be understood that the foregoing detailed description is for illustration only and that various changes in parts, as well as the substitution of equivalent constituents for those shown and described, may be made without departing from the spirit and scope of the invention as set forth in the appended claims.
A tool that is particularly suitable for the installation of objects that require tensioning and severing. A tensioning member is operated through a toggle linkage that collapses when a pre-determined level of tensioning is reached and actuates a cutoff lever. The result is severence of the tensioned object with reduced shock loading. In addition the tool is easy to operate; the tensioning level is accurately and reliably adjustable; and the severed object is controllably ejected from the tool.
5
This application is a divisional of copending application Ser. No. 09/716,706, filed Nov. 20, 2000, now pending. FIELD OF THE INVENTION The present invention relates to a noble metal containing hydrogenation catalyst for the selective hydrogenation of 1,4 butynediol to 1,4 butenediol. The present invention also relates to a process for the preparation of the said catalyst. More particularly, the present invention relates to said hydrogenation catalyst for the selective preparation of 1,4 butynediol to 1,4 butenediol, and a process for the preparation of the said catalyst. BACKGROUND OF THE INVENTION 1,4 butenediol is a useful intermediate in the production of pesticide, insecticide and vitamin B 6 . Being an unsaturated diol it can be used in the synthesis of many organic products such as tetrahydrofuran, n-methyl pyrrolidione, γ-butyrolactone, etc. It is also used as an additive in the paper industry, as a stabiliser in resin manufacture, as a lubricant for bearing systems and in the synthesis of allyl phosphates. Prior art discloses the use of a number of catalysts for the manufacture of 1,4 butenediol by the hydrogenation of 1,4 butynediol. Most of the prior art patents are based on a combination of palladium with one or more mixed compounds of copper, zinc, calcium, cadmium, lead, alumna, mercury, tellurium, gallium, etc. GB A 871804 describes the selective hydrogenation of acetylinic compound in a suspension method using a Pd catalyst which has been treated with the salt solutions of Zn, Cd, Hg, Ga, Th, In, or Ga. The process is carried out at milder conditions with 97% selectivity for cis 1,2-butenediol and 3% to the transform. Moreover, use of organic amines have been suggested as promoters in the catalyst system. U.S. Pat. No. 2,681,938 discloses the use of a Lindlar catalyst (lead doped Pd catalyst), for the selective hydrogenation of acetylinic compounds. The drawback of this process is the use of additional amines such as pyridine to obtain good selectivity for 1,4 butenediol. German patent DE 1, 213, 839 describes a Pd catalyst doped with Zn salts and ammonia for the partial hydrogenation of acetylinic compounds. However, this catalyst suffers from the drawback of short lifetime due to poisoning. German patent application DE A 2, 619, 660 describes the use of Pd/Al 2 O 3 catalyst that has been treated with carbon monoxide for the hydrogenation of butynediol in an inert solvent. The disadvantage of this catalyst is that is treated with carbon monoxide gas which is highly toxic and difficult to handle. U.S. Pat. No. 2,961,471 discloses a Raney nickel catalyst useful for the partial hydrogenation of 1,4 butynediol. The catalyst of this process gives a low selectivity for 1,4 butenediol. Another U.S. Pat. No. 2,953,604 describes a Pd containing charcoal and copper catalyst for the reduction of 1,4 butynediol to 1,4 butenediol with 81% selectivity for 1,4 butenediol. However, this process results in the formation of a large number of side products and is therefore undesirable. U.S. Pat. No. 4,001,344 discloses the use of palladium mixed with γ-Al 2 O 3 along with both zinc and cadmium or either zinc or cadmium together with bismuth or tellurium for the preparation of 1,4 butenediol by the selective hydrogenation of 1,4 butynediol. However, a large number of residues are formed (7.5-12%) which lowers the selectivity of 1,4 butenediol to 88%. U.S. Pat. Nos. 5,521,139 and 5,278,900 describes the use of a Pd containing catalyst for the hydrogenation of 1,4 butynediol to prepare 1,4 butenediol. The catalyst used is a fixed bed catalyst prepared by applying Pd and Pb or Pd and Cd successively by vapor deposition or sputtering to a metal gauze or a metal foil acting as a support. In this process also the selectivity obtained for cis 1,4 butenediol is 98%. The disadvantage of this process is that a trans butenediol with residues are also obtained. All the above catalysts for the hydrogenation of butynediol to butenediol suffer from disadvantages such as they contain more than two metals along with other promoters such as organic amines. Their preparation becomes cumbersome and all the reported catalysts do not give complete selectivity for the desired product 1,4 butenediol. The formation of side products and residues have also been reported which affect the efficiency of the process and the recovery of pure 1,4 butenediol is difficult. Another disadvantage that prior art catalysts suffer from is short life due to fast deactivation. It is therefore important to obtain and/or develop catalysts that overcome the disadvantages of prior art catalysts used in the hydrogenation of 1,4 butynediol to 1,4 butenediol enumerated above. OBJECTS OF THE INVENTION The main object of the invention is to provide a novel hydrogenation catalyst for the selective preparation of 1,4 butenediol that comprises a noble metal, individually or in combination with nickel, on a suitable support without poisoning at very specific preparation conditions for the selective production of 1,4 butenediol. It is another object of the invention to provide a process for the preparation of such novel hydrogenation catalysts for the preparation of 1,4 butenediol. It is another object of the invention to provide a novel hydrogenation catalyst for the preparation of 1,4 butenediol that results in 100% conversion of the butynediol and 100% selectivity at mild process conditions. It is another object of the invention to provide a catalyst with high stability that can be recycled several times without loss of activity and selectivity. It is another object of the invention to provide a process for the preparation of 1,4 butenediol using the hydrogenation catalyst of the invention. It is another object of the invention is to provide a novel catalyst for the selective hydrogenation of 1,4 butynediol to 1,4 butenediol that comprises only platinum on a suitable support, without poisoning at very specific preparation conditions. It is an object of the invention to provide a process for the preparation of 1,4 butenediol from 1,4 butynediol using a novel hydrogenation catalyst resulting in 1,4 butenediol of high purity by mere separation of the catalyst. SUMMARY OF THE INVENTION Accordingly the present invention provides a hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from palladium and platinum, y=0.2 to 10%, C is nickel and z=0 to 15.0% with the proviso that when B is Pt, z=0. In one embodiment of the invention, B is Pd and z=0.2-10%. The present invention also relates to a process for the preparation of a hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from palladium and platinum, y=0.2 to 10%, C is nickel and z=0 to 15.0% with the proviso that when B is Pt, z=0, said process comprising: i. dissolving a noble metal precursor in a mineral acid by stirring at a temperature in the range between 60° C. to 120° C.; ii. diluting the above solution by adding water; iii. adjusting the pH of the solution to the range of 8-12 by adding a base; iv. adding a support to the above solution; v. heating the mixture to a temperature in the range of 60° C. to 120° C.; vi. reducing the above mixture using a conventional reducing agent; vii. separating the catalyst formed by any conventional method; viii. washing and drying the product to obtain the said catalyst. In a further embodiment of the invention, the noble metal comprises of palladium and z=0.2 to 15%, the catalyst obtained at the end of step viii above is mixed with a solution of nickel in a basic medium having a pH in the range of 8-12, the mixture stirred for about 1 hour and the catalyst is separated by any conventional method. The catalyst is then dried at about 150° C. up to 10 hours in static air, reduced at a temperature in the range of between 390-420° C. for a time period in the range of between 5-12 hours in a flow of hydrogen, the reduced catalyst is then separated by any conventional method and washed and dried to obtain the final catalyst containing palladium and nickel. In one embodiment of the invention, the noble metal source is a noble metal salt selected from the group consisting of acetate, bromide, and chloride and the source of nickel is a salt of nickel selected from the group consisting of acetate, carbonate, chloride and nitrate. In another embodiment of the invention, the support is a Group II A metal salt selected from the group consisting of acetates, nitrates, chlorides and carbonates of magnesium, calcium and barium and the source of zeolite is NH 4 -ZSM5. In a further embodiment of the invention, the base used may be selected from the group consisting of sodium carbonate, potassium carbonate, potassium hydroxide, and sodium hydroxide. In another embodiment of the invention, the reducing agent used is selected from the group consisting of hydrazine hydrate, hydrogen containing gas, and formaldehyde. The present invention also relates to a process for the preparation of 1,4 butenediol from 1,4 butynediol said process comprising subjecting the 1,4 butynediol to hydrogenation by any conventional method characterised in that the catalyst used for the hydrogenation is of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from palladium and platinum, y=0.2 to 10%, C is nickel and z=0 to 15.0%. In a further embodiment of the invention, the selectivity of the process at milder process conditions is 100% The present invention also relates to the use of a novel hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal, y=0.2 to 10%, C is nickel and z=0 to 15.0%, for the preparation of 1,4 butenediol. DETAILED DESCRIPTION OF THE INVENTION The present invention achieves 100% conversion of 1,4 butynediol with 100% selectivity for cis 1,4 butenediol at mild process conditions. At higher temperatures, while 1,4 butynediol is converted completely, the selectivity for cis 1,4 butenediol is less, generally <90%. The formation of side products such as acetals, γ-hydroxybutaraldehyde, butanol at higher temperatures is also more pronounced. The hydrogenation of 1,4 butynediol to 1,4 butenediol is carried out in an autoclave under stirring conditions in the presence of Pd or Pt containing catalyst suspended in a mixture of 1,4 butynediol in water at 50° C. and 350 psig of H 2 pressure. The mixture is made alkaline (pH=8-10) by the addition of ammonia. Before pressurising the autoclave, it was ensured that there was no air in the autoclave. The hydrogenation is complete when the absorption of hydrogen is stopped or unchanged. After the reaction was complete, the reactor was cooled below ambient temperature and the contents were discharged and the reaction mixture analysed using a gas chromatography. The catalyst prepared as per the procedure described below in the examples can be reduced in a muffle furnace at 400° C. in hydrogen flow for a time period ranging between 5-12 hours, preferably 7 hours. In a feature of the invention, high purity 1,4 butenediol can be simply obtained by the removal of the catalyst from the product stream. The present invention is described below by way of examples. However, the following examples are illustrative and should not be construed as limiting the scope of the invention. EXAMPLE 1 Preparation of 1% Pd/MgCO 3 Catalyst 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the palladium chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.02 gms of magnesium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 2 Preparation of 1% Pd/CaCO 3 Catalyst 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.12 gms of calcium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 3 Recycling of 1% Pd/CaCO 3 Catalyst This example illustrates the recycling of 1% Pd/CaCO3 catalyst wherein the catalyst preparation was similar to the disclosure in Example 2 above. The hydrogenation of 1,4 butynediol was carried out by recycling the catalyst 10 times at 50° C. and 350 psig H 2 pressure as described earlier. EXAMPLE 4 Preparation of 1% Pd/BaCO 3 Catalyst 0.16 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the palladium chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.1 gms of barium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 5 Preparation of 1% Pd/NH 4 -ZSM5 Catalyst 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the palladium chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.0 gms of NH 4 -ZSM5 was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 6 Preparation of 10% Ni— 1% Pd/CaCO 3 Catalyst 0.17 gms of palladium chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.12 gms of calcium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. The dried catalyst is then mixed with a solution of nickel nitrate and stirred in basic medium (pH=9-10) for 1 hour, dried at 150° C. for 10 hours in static air and then reduced at 400° C. for 7 hours in a flow of hydrogen. EXAMPLE 7 Preparation of 1% Pt/MgCO 3 Catalyst 0.16 gms of platinum chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.13 gms of magnesium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 8 Preparation of 1% Pt/CaCO 3 Catalyst 0.17 gms of platinum chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.03 gms of calcium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 9 Preparation of 1% Pt/BaCO 3 Catalyst 0.16 gms of platinum chloride was dissolved in 4 ml of hydrochloric acid and stirred at 80° C. till the platinum chloride was completely dissolved. The resultant solution was diluted by adding 50 ml of water and stirring for 2 hours, the pH being maintained between 9-10 by the addition of sodium hydroxide. To the diluted solution, 10.05 gms of barium carbonate was added and the mixture heated at 80° C. for 1 hour. The mixture was then reduced by the addition of formaldehyde (3 ml), stirred for 45 minutes, filtered and washed with water till the solution is alkaline free. The catalyst was then dried at 150° C. for 10 hours. EXAMPLE 10 Performance of Palladium or Palladium and Nickel Supported Catalysts of the Invention as Prepared in Examples 1-6 Above This example illustrates the performance of the palladium or palladium and nickel supported catalysts of the invention as prepared in Examples 1-6 above in the hydrogenation of 1,4 butynediol to 1,4 butenediol. Conversion Selectivity to of 1, 4 cis 1, 4 Reaction Example butynediol butenediol period No. Catalyst (%) (%) (hours) 1 1% Pd/MgCO 3 100 99.8 2 2 1% Pd/CaCO 3 100 98.2 1 3 1% Pd/CaCO 3 * 100 98 68 4 1% Pd/BaCO 3 100 100 2 5 1% Pd/NH 4 -ZSM 5 100 100 4 6 10% Ni- 1% 100 100 4 Pd/CaCO 3 *catalyst recycled for 10 times EXAMPLE 11 Performance of Platinum Supported Catalysts of the Invention as Compared in Examples 7-9 Above This example illustrates the performance of the platinum supported catalysts of the invention as prepared in Examples 7-9 above in the hydrogenation of 1,4 butynediol to 1,4 butenediol. Conversion of 1, 4 Selectivity Reaction Example butynediol to cis 1,4 period No. Catalyst (%) butenediol (%) hours 7 1% Pt/MgCO 3 100 99.8 2 8 1% Pt/CaCO 3 100 100 1 9 1% Pt/BaCO 3 100 99.9 2.5 ADVANTAGES OF THE INVENTION 1. The catalyst of the invention is useful for the selective hydrogenation of 1,4 butynediol to 1,4 butendiol without poisoning. 2. Substantially complete conversion of 1,4 butynediol to 1,4 butenediol with almost 100% selectivity to cis 1,4 butenediol is obtained at milder process conditions. 3. The separation of the product 1,4 butenediol in pure form is achieved easily by the removal of the catalyst from the reaction mixture. 4. The catalyst of the invention is capable of recycling several times without loss of activity or selectivity. The turn over number also is good.
A hydrogenation catalyst of the general formula AB(y)C(z) wherein A is a support comprising of a salt of a Group II A metal or zeolite, B is a noble metal selected from Pt or Pd, y=0.2 to 10%, C is nickel and z=0 to 15.0%, with the proviso that when B is Pt, z=0.
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CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the priority of Korean Patent Application No. 2010-0085609 filed on Sep. 1, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference. SEQUENCE LISTING The instant application contains a Sequence Listing which has been submitted in ASCII format via EFS-Web and is hereby incorporated by reference in its entirety. Said ASCII copy, created on Jan. 30, 2014, is named 87958-302663_ST25.txt and is 20,954 bytes in size. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for promoting plant biomass by overexpression of a small GTP binding protein RabG3b, a vector including the relevant gene, a transgenic plant including the vector and a method for producing the same. 2. Description of the Related Art In general, specifically modified plants may be acquired using molecular technology in agriculture, gardening, biomass conversion and other industries (i.e., paper industry, protein or plant as the production factor for other compounds). For example, excellent utility of crop cultivation may be generated from controlling the size of plant as the overall organs or any parts of the organs, or any number of organs. Similarly, controlling the size and the height of plant, its specific portion, its rate of growth or seedling vitality enables production of more suitable plants in specific industries. For example, decrease in the height of specific crops and species of trees may be useful according to easier harvesting. Alternatively, the increased height and thickness of the plant, or the size and the number of organs may be made efficient by supplying much more biomass that is useful for processing into food, feed, fuel and/or chemicals. (Refer to the website of United States Department of Energy on energy efficiency and regeneration). Other examples of commercially desirable features include increase in length of the stem of cut flowers, increase or change in the size and shape of leaves, promotion of seeds and/or fruits. Changes in the size and the number of organs, and biomass also lead to change in the weight of components such as the secondary products and conversion into manufacture of compounds which are derived from plant. Experts and researchers in the fields of Agricultural Science, Agriculture, Crop Science, Gardening, and Forest Science have made continuous efforts to effectively search and produce plants which show increased growth in order to secure the supply of foods and renewable materials to a fast-growing population over the world. In such science fields, their complicated researches point out that they are important leaders in all geographical environments and climates over the world, in supply of sustainable sources of foods, feeds and energy to the group. Manipulation of performance of agricultural products has been conventionally achieved through plant breeding for centuries. However, such breeding procedure is time-consuming and labor-intensive. Moreover, breeding programs should be specifically designed for relative species of plants. On the other hand, molecular genetic approaches have been used as an excellent procedure in order to prepare plants that produce better crops. Using introduction and expression of recombinant nucleic acid molecules in the plant, researchers are now prepared for supplying the group with species of plants which are adjusted for more efficient growth and more products, regardless of specific geographical and/or climatic environments. Their new approaches have an additional advantage of applying to other complex species of plants, without being restricted to one species of plant (Zhang et al. (2004) Plant Physiol. 135:615). Regardless of this procedure, generally applicable procedures are currently required to improve the growth of plants in forest and agricultural industry for the purpose of satisfying specific requests, which depends on specific environmental conditions. Finally, the present invention relates to useful manipulation of the size of plant, the number of organ, the plant's rate of growth, the plant structure and/or biomass in order to make plants grow, seek profits specified by expression of recombinant DNA molecules and maximize profits of various agricultural products which are dependent on a specific environment. These molecules may be originated from the plant itself or simply expressed at a higher or lower level. Moreover, they may be originated from other species of plants. SUMMARY OF THE INVENTION Accordingly, the present invention is designed to solve the above-mentioned problems, it is an object of the present invention to provide a protein associated with promotion of plant biomass. It is another object of the present invention to provide a gene associated with promotion of plant biomass. It is still another object of the present invention to provide a method for promoting plant biomass using the gene. It is still another object of the present invention to provide a method for producing a transgenic plant including the gene. It is yet another object of the present invention to provide the transgenic plant. According to an aspect of the present invention, there is provided a method for promoting plant biomass by preparation of a small GTP binding protein, RabG3b or mutants of the RabG3b protein and overexpression of genes coding the RabG3b protein or the mutants of the RabG3b protein. The term “biomass” used in the present invention means a useful biological material including target products, and the material is designed and recovered in additional procedures to separate or concentrate the target products. The term “biomass” may include fruits or their portions, or seeds, leaves, or stems or roots, and they are particularly parts of plants of interest for industrial purpose. As plant materials are mentioned above, the term “biomass” includes any of a structure(s) including or representing the target products. The term “transformation” used in the present invention includes Agrobacterium -mediated transformation [transformation of dicotyledonous plant (Needleman and Wunsch (1970) J. Mol. Biol. 48:443; Pearson and Lipman (1988) Proc. Natl. Acad. Sci. (USA) 85: 2444), transformation of monocotyledonous plant (Yamauchi et al. (1996) Plant Mol. Biol. 30:321-9; Xu et al. (1995) Plant Mol. Biol. 27:237; Yamamoto et al. (1991) Plant Cell 3:371)] and the biolistic method (P. Tijessen, “Hybridization with Nucleic Acid Probes” In Laboratory Techniques in Biochemistry and Molecular Biology, P. C. vand der Vliet, ed., c. 1993 by Elsevier, Amsterdam), electroporation, in planta technology, etc., and examples of means for transformation will be described below. For the plant including exogenous nucleic acids, the first transgenic plant is referred to as T 0 and the first generation is referred to as T 1 in the present invention. According to one exemplary embodiment of the present invention, the used RabG3b protein and a gene sequence coding the RabG3b protein are derived from Arabidopsis thaliana , and RabG3b gene from other species of interest or pseudo-gene may be also used. According to another exemplary embodiment, the RabG3b protein preferably has an amino acid sequence set forth in SEQ ID NO: 1, but all mutants, which are obtained by mutation of plants through substitution, deletion and addition of any one or more amino acids in the amino acid sequence set forth in SEQ ID No. 1 and show a desired promotion of biomass in the present invention, are included in the scope of the present invention, and examples of the mutants are mutants having a sequence in which a 67 th residue is substituted from glutamine to leucine in the amino acid sequence set forth in SEQ ID NO: 1. However, the gene coding the protein or its mutants preferably have a substantial homology to nucleic acid sequence set forth in SEQ ID NO: 2 or 3, but the present invention is not limited thereto. In the present invention, the term “substantial homology” of poly nucleotide sequence means a polynucleotide including a sequence showing sequence homology of 60% or higher, normally 70% or higher, and more normally 80% or higher, and most preferably 90% or higher, when a standard parameter is used to compare with a reference sequence in a program described below. Those skilled in the art may recognize that such values may be properly adjusted for measurement of the corresponding identity of a protein encoded by a pair of nucleotide sequences with consideration of codon degeneracy, amino acid similarity and reading frame localization. An example of algorithm is a BLAST algorithm described in the previous studies (see: Altschul et al., J. Mol. Biol. 215:403-410, 1990), that is suitable for measurement of percentage of sequence homology and similarity. Software for BLAST analysis is available through the web site of National Center for Biotechnology Information (NCBI). According to another exemplary embodiment, the gene expression is preferably under the control of a promoter. As the promoter which is suitable for expression while being operationally linked a gene associated with promotion of plant biomass using methods described in the present invention, a promoter originating from the same or different species of transgenic plant may be used. Moreover, the promoter may originate from the same or the different species in aspect to the gene to be used in the present invention. The promoter for use in the present invention may also include a chimera promoter that may include a combination of promoters which have one or more common expression profiles compared to what will be described below. Methods of determining and characterizing a promoter region in plant genomic DNA have been well known to those skilled in the art. For example, they are described in the previous studies [see: Jordano et al, Plant Cell 1: 855-866, 1989; Bustos et al., Plant Cell 1: 839-854, 1989; Green et al., EMBO J. 7: 4035-4044, 1988; Meier et al., Plant Cell 3: 309-316, 1991; and Zhang et al., Plant Physiol. 110: 1069-1079, 1996]. Examples of this promoter sequence include a promoter for amino acid permease gene (AAP1)(ex: an AAP1 promoter from Arabidopsis thaliana ) (see: Hirner et al., Plant J. 14: 535-544, 1998), a promoter for an oleate 12-hydroxylase:desaturase gene (ex: a promoter designated as LFAH12 from Lesquerella fendleri (see: Broun et al., Plant J. 13: 201-210, 1998), a promoter for a 2S2 albumin gene (ex: a 2S2 promoter from Arabidopsis thaliana ) (see: Guerche et al., Plant cell 2: 469-478, 1990), a fatty acid elongase gene promoter (FAEI) (ex: FAE1 promoter from Arabidopsis thaliana ) (see: Rossak et al., Plant Mol. Biol. 46: 717-715, 2001), and a leafy cotyledon gene promoter (LEC2) (ex: a LEC2 promoter from Arabidopsis thaliana ) (see: Kroj et al Development 130: 6065-6073, 2003). Moreover, the present invention provides an expression vector for promoting plant biomass comprising a nucleic acid sequence that encodes a RabG3b gene operationally linked to one or more regulatory genes that can promote the expression of plant biomass-related genes. In the present invention, the term “vector” or “expression vector” generally means a double DNA strand that may be used to insert the vector into exogenous DNA. For example, a vector or a replicon may originate from plasmid or virus. The vector contains “replicon” polynucleotide sequence to promote self-replication of vector in a host cell. Moreover, the term “replicon” used in the art contains a polynucleotide sequence that targets a recombination of a vector sequence into a host chromosome promotes other replications. Moreover, even when the exogenous DNA may be, for example, inserted into a viral DNA vector in an early stage, transformation of viral vector DNA into the host cell may lead to transcription of viral DNA into viral RNA vector molecules. The exogenous DNA is defined as xenogenic DNA, for example, as DNA that isn't naturally found in the host cell. Here, the DNA serves to replicate and select the vector molecules or encode selectable markers or transgenes. The vector is used to transmit exogenous or xenogenic DNA into a suitable host cell. In the host cell, the vector may replicate independently or differently from host chromosomal DNA, and may form several copies of vectors and DNA inserted into the vectors. Moreover, the vector may target insertion of exogenous or xenogenic DNA into the host chromosome. The vector, also, may permit transcription of inserted DNA into mRNA molecules, or contain essential elements to induce replication of inserted DNA into a large copy number of RNA. Some expression vectors further include sequence elements which are close to inserted DNA that permits translation of mRNA into protein molecules. Accordingly, polypeptides encoded by many mRNAs and inserted DNA may be promptly synthesized. The term “transformation vector” used in the present invention means an inserted DNA fragment, in other words, a “transgene” that is inserted into mRNA or replicated as RNA in a host cell. The term “transgene” in the present invention doesn't mean an inserted DNA fragment to be transcribed into RNA, but means a vector region required for transcription or replication into RNA. Moreover, the transgene doesn't need to essentially contain a polynucleotide sequence comprising open reading frames that may be used to produce proteins. The terms “transformed host cell,” “transformed” and “transformation” in the present invention mean introduction of DNA into a cell. The cell is named as a “host cell,” which may be a prokaryotic or eukaryotic cell. One example of representative prokaryotic host cell includes all kinds of E. coli strains. One example of representative eukaryotic host cell includes plant cells (ex: Canola, raw cotton, Camelina, Alfalfa, soybean, rice plant, oat, wheat or corn cells), yeast cells, insect cells or animal cells. Generally, introduced DNA is in the form of a vector containing an inserted DNA fragment. A sequence of the introduced DNA may originate from a same or different species of the host cell, or may be a hybrid DNA sequence containing several DNAs and several exogenous DNAs which may originate from the host cell. In the present invention, the term “plant” includes the overall plants, plant organs (ex: leaves, stems, flowers, roots, etc.), seeds and plant cells (including tissue culture cells) and offspring thereof. In general, a group of plants which may be used in the methods of the present invention are widely varied from a group of higher plants including both monocots and dicots which are applicable to transformation technology to a group of lower plants such as algae. They include all kinds of polyploid plants including polyploidy, diploid and haploid. The transgenic plant overexpressing RabG3b of the present invention may be, for example, obtained by transfection of a gene transfer vector (ex: plasmid, viral vector, etc.) encoding promoters operationally linked to the RabG3b gene into the plant. Conventionally, when a vector is plasmid, the vector includes a selectable marker gene, for example, a kanamycin gene encoding tolerance to kanamycin. The most general method for transformation of a plant includes: cloning a target transgene into a plant transformation vector, and transforming the plant transformation vector into Agrobacterium tumifaciens including a helper Ti-plasmid, as described in the previous studies [see: Hoeckeme et al., Nature 303: 179-181, 1983]. For example, an additional method is described in the previous studies (see: Maloney et al., Plant Cell Reports 8: 238, 1989). Agrobacterium cell containing the transformation vector may be cultivated with leaf lobes of the plant to be transformed, as described in the previous studies (see: An et al., Plant Physiol. 81: 301-305, 1986; Hooykaas, Plant Mol. Biol. 13: 327-336, 1989). As conventionally described above, the transformation of cultivated plant host cell may be achieved using Agrobacterium tumefaciens . In general, a culture extract of the host cell that does not have a solid cell membrane barrier is originally described in the previous studies (see: Graham et al., Virology 52: 546, 1978) and transformed using a transformed calcium phosphate method, as described in the previous studies (see: Sambrook et al., Molecular Cloning: A Laboratory Manual (2nd Ed., 1989 Cold Spring Harbor Laboratory Press, New York, N.Y.). However, another method for introducing DNA into cells may also be used, which includes a polybrene test (see: Kawai et al., Mol. Cell. Biol. 4: 1172, 1984), a protoplast fusion (see: Schaffner, Proc. Natl. Acad. Sci. USA 77: 2163, 1980), electroporation (see: Neumann et al., EMBO J. 1: 841, 1982) and direct microinjection into the nucleus (see: Capecchi, Cell 22: 479, 1980). Transformed plant cells may be, for example, selected with a selectable marker by cultivating cells on medium containing a phytohormone such as kanamycine, naphthalene acetic acid and benzyladenine, which are used to induce formation of callus and shoots. Afterwards, plants obtained by regeneration of the plant cells may be transferred to the soil using technologies widely known to those skilled in the art. In addition to the above-mentioned methods, a large number of methods are widely known in the art, which includes transferring the cloned DNA into various species of the plants including gymnosperm, sporic plant, monocot and dicot [see: Glick and Thompson, eds., Methods in Plant Molecular Biology and Biotechnology, CRC Press, Boca Raton, Fla., 1993; Vasil, Plant Mol. Biol, 25: 925-937, 1994; and Komai et al., Current Opinions Plant Biol. 1: 161-165, 1998 (general review); Loopstra et al., Plant Mol. Biol. 15: 1-9, 1990; and Brasileiro et al., Plant Mol. Biol. 17: 441-452, 1990 (tree transformation); Eimert et al., Plant Mol. Biol. 19: 485-490, 1992 ( brassica transformation); Hiei et al., Plant J. 6: 271-282, 1994; Hiei et al., Plant Mol. Biol. 35: 205-218, 1997; Chan et al., Plant Mol. Biol. 22: 491-506, 1993; U.S. Pat. Nos. 5,516,668 and 5,824,857 (rice plant transformation); and U.S. Pat. No. 5,955,362 (wheat transformation); U.S. Pat. No. 5,969,213 (monocot transformation); U.S. Pat. No. 5,780,798 (corn transformation); U.S. Pat. No. 5,959,179 and U.S. Pat. No. 5,914,451 (soybean transformation)]. Representative examples include protoplast electroporation-accelerated DNA absorption (see: Rhodes et al., Science 240: 204-207, 1988; Bates, Meth. Mol. Biol. 111: 359-366, 1999; DHalluin et al., Meth. Mol. Biol. 111: 367-373, 1999; U.S. Pat. No. 5,914,451); protoplast treatment using polyethylene glycol (see: Lyznik et al., Plant Mol. Biol. 13: 151-161, 1989; Datta et al., Meth. Mol. Biol., 111: 335-334, 1999); and bombardment of cells using microprojection containing DNA (see: Klein et al., Plant Physiol. 91: 440-444, 1989; Boynton et al., Science 240: 1534-1538, 1988; Register et al., Plant Mol. Biol. 25: 951-961, 1994; Barcelo et al., Plant J. 5: 583-592, 1994; Vasil et al., Meth. Mol. Biol. 111: 349-358, 1999; Christou, Plant Mol. Biol. 35: 197-203, 1997; Finer et al., Curr. Top. Microbiol. Immunol. 240: 59-80, 1999). In addition, plant transformation steps and technologies are found in the previous studies (see: Birch, Ann. Rev. Plant Phys. Plant Mol. Biol. 48: 297, 1997; Forester et al., Exp. Agric. 33: 15-33, 1997). Their slight variation enables the technologies in the art to be applicable to wide-ranging species of the plants. For transformation of monocots, particle bombardment is a conventional selection method. However, monocots such as corn may be also transformed using Agrobacterium transformation method as described in U.S. Pat. No. 5,591,616. Another method for transformation of monocots such as corn includes, for example, mixing cells from an embryonic suspension culture with a fiber suspension [5% w/v, Silar SC-9 whiskers] and plasmid DNA (1 μg/μl) and horizontally keeping the cells in a large number of sample heads in a Vortex GENIE II vortex mixer [manufactured by Scientific Industries, Inc., located in Bohemia, N.Y., U.S.] or in a holder of a MIXOMAT dental amalgam mixer [manufactured by Degussa Canada Ltd., located in Ontario, Burlington, Canada]. Then, transformation may be performed by mixing for approximately 60 seconds (for example, using Vortex GENIE II) at the highest speed or shaking at a regular speed for 1 second (MIXOMAT). According to the process of the present invention, a group of cells from which stable transformants may be screened are produced. Then, the southern hybrid analysis may be used to regenerate plants from stably transformed callus and transform the plants and their offspring. For example, U.S. Pat. No. 5,464,765 discloses the use of plants cells, particularly corn silk for corn transformation. U.S. Pat. No. 5,968,830 discloses a method for transforming and regenerating soy beans. Moreover, U.S. Pat. No. 5,969,215 discloses a transformation technology for producing a transformed Beta vulgaris plant as sugar beet. The above-mentioned transformation technologies have their advantages and disadvantages. In each technology, genetic manipulation of DNA from plasmid makes it possible to contain a selectable and screenable marker gene as well as a target gene. The screenable marker gene may be used to select only cells with integrated copies of plasmid (a construct of the present invention is used to transform a target gene and a screenable gene as units). Such screenable gene provides other inspections for successful cultivation of cells with the target gene only. Conventional Agrobacterium transformation using a screenable marker of antibiotic resistance may be problematic since these transformed plants may have high risk in spreading antibiotic resistance to animals and human beings. Such antibiotic marker may be removed from plants by producing a transformed plant using the Agrobacterium technology similar to the technology is described in U.S. Pat. No. 5,731,179. The antibiotic resistance-related problems may be effectively avoided using a bar or pat encoding sequence, as described in U.S. Pat. No. 5,712,135. Such desirable marker DNA encodes a secondary protein or polypeptide that suppresses or neutralizes actions of a glutamine synthetase inhibitor, a weed-killer, phosphinothricin (Glufosinate) and Glufosinate-ammonium salt (Basta, Ignite). Plasmid containing at least one of these genes is introduced into plant protoplast or callus using one of the technologies described above. When the marker gene is a screenable gene, only cells including a DNA package survive under the screening conditions using a proper plant toxin. When proper cells are screened and grown, their plants are regenerated. It is confirmed that the DNA package is successfully integrated into plant genome by testing the offspring from the transformed plants. There are a large number of factors that affect the success of transformation. Components for designing, constructing and controlling an exogenic gene construct may affect integration of an exogenic sequence chromosomal DNA of the plant nucleus and an ability of a transgene to be expressed by cells. It is essential to introduce the exogenic gene construct into the plant nucleus using a non-toxic method. It is important to provide a proper regeneration protocol because a cell type into which the construct is introduced may be adjusted for regeneration when the overall plants are recovered. Moreover, a prokaryotic cell may be used as a host cell at an initial cloning stage according to the present invention. Methods, vectors, plasmid and host cell systems are well known to those skilled in the art, which may be used at such initial cloning and expansion stages and will not be described in the present invention. According to another exemplary embodiment of the present invention, a promoter may be operationally linked to genes that may encode plant biomass promotion-related genes such as RabG3b in plants to be transformed using methods widely known to those skilled in the art. Insertion of the promoter leads to gene expression in developing seeds of transgenic plants. In the method of the present invention, the transgenic plant includes monocots and dicots, but the present invention is not limited thereto. Among them, plants of interest include Canola, raw cotton, wheat, rice plant, soybean, barley and other seed-producing plants, and Alfalfa. Also, the plants of interest includes, but is not limited to, other plants, and all agricultural, commercial and other industrial plants of interest. The term “xenogeneic sequence” used in the present invention means an oligonucleotide sequence that is substantially modified from its original type, when such sequence originates from the different or same species. For example, a xenogeneic promoter operationally linked to a structural gene originates from a species different from that of the structural gene, or originates from a species that is substantially modified from its original type when the sequence originates from the same species. The term “primer” used in the present invention is a separated nucleic acid that annealed with a complementary target DNA strand through nucleic acid hybridization, thus forming a hybrid between the primer and target DNA strand, and then is extended along the target DNA strand by means of polymerase, for example, DNA polymerase. A pair of primers according to the present invention may be used to amplify a target nucleic acid sequence using polymerase chain reaction (PCR) or other conventional nucleic acid amplification methods. Methods for preparing and using probes and primers are, for examples, described in the studies (Molecular Cloning: A Laboratory Manual, 2nd ed., vol. 1-3, ed. Sambrook et al., Cold Spring Harbor Laboratory Press, Cold Spring Harbor, N.Y., 1989 (hereinafter, “Sambrook et al., 1989”); Current Protocols in Molecular Biology, ed. Ausubel et al., Greene Publishing and Wiley-Interscience, New York, 1992 (periodically revised) (hereinafter, “Ausubel et al., 1992”); and Innis et al., PCR Protocols: A Guide to Methods and Applications, Academic Press: San Diego, 1990). Pairs of PCR primers may be, for example, derived from known sequences using a computer programs such as Primer (Version 0.5, © 1991, Whitehead Institute for Biomedical Research, Cambridge, Mass.) developed for this purpose. For the nucleic acid amplification, any of various nucleic acid amplification methods including PCR as known in the art may be used. Various amplification methods are known to those skilled in the art, and particularly described in U.S. Pat. No. 4,683,195 and U.S. Pat. No. 4,683,202, and PCR Protocols: A Guide to Methods and Applications, ed. Innis et al., Academic Press, San Diego, 1990. PCR amplification methods have been advanced to amplify genomic DNA of maximum 22 kb and bacteriophage DNA of maximum 42 kb (Cheng et al., Proc. Natl. Acad. Sci. USA 91: 5695-5699, 1994). Hereinafter, the present invention will be described. A tracheary element (hereinafter, referred to as ‘TE’) of xylem serves as xylem for transporting water in the vascular system. For this, TE proceeds into secondary cell wall thickening and cell death. The cell death of TE is typical embryologically programmed cell death by autophagy. However, there is no known evidence about the autophagy in TE differentiation. The present invention has found that a small GTP binding protein, RabG3b, participates in the TE differentiation through action of the autophagy. It was found that the differentiation of wild-type TE cells undergo the autophagy in an Arabidopsis culture system. Both of the autophagy and TE differentiation are remarkably accelerated by continuous overexpression of an activated mutant (RabG3bCA) and suppressed in transformed plants overexpressing a dominant-negative mutant (RabG3bDN) or RabG3b RNAi, a brassinosteroid insensitive mutant bri1-301, and an autophagy mutant atg5-1. Based on these results, the present invention suggests that the autophagy occurs during the TE differentiation, and RabG3b as a component of the autophagy serves to control the TE differentiation. The cell death occurring in the last stage of development of xylem, particularly, differentiation of duct cells is a very important procedure for completion of xylem. Because all contents of protoplasm are disintegrated during this procedure to form hollow xylem. According to the present invention, it is confirmed that autophagy accelerates the cell death in such xylem development. Finally, when RabG3bCA in a constitutively active type of RabG3b participating in the autophagy is overexpressed, the autophagy is accelerated during the xylem development, which leads to accelerated cell death, thus promoting development of xylem in the plant stem. The importance of the present invention is as follows. Xylem is a tissue that forms a wood layer in plants. Accordingly, when the same characters (i.e., increase of xylem) as observed from Arabidopsis thaliana are formed by overexpressing overexpressed RabG3bCA according to the present invention in plants, these characters are very important since they are applicable in industries. This is because it means promotion of plant biomass. For now, trees such as poplar or eucalyptus are used as a representative wood material. Wood is the main material for pulp and paper. Moreover, it has come into the spotlight as an important material of production of bioethanol (next-generation alternative energy), which is one of the current hot issues. Hereinafter, the present invention will be described in more detail. RabG3b Functions for Xylem Differentiation. The small GTP binding protein RabG3b was identified as a salicylic acid reaction protein by proteomic analysis (Oh et al., 2005). Microarray analysis showed that RabG3b is highly expressed in response to brassinolide (BL)/H 3 BO 3 treatment ( FIG. 12 ). The present invention examined (1) whether RabG3b participates in TE differentiation, (2) whether RabG3b participates in autophagy and (3) whether autophagy participates in TE differentiation. RabG3b knockdown plant (RabG3bRNAi) was produced, in which RabG3b expression was reduced among a member of tested RabG3 family, and RabG3b proteins were not significantly detected by Western Blot Analysis ( FIG. 13 ). Two different RabG3b transgenic plants, RabG3bCA and RabG3bDN representing a continuously active (CA) and dominant-negative (DN) mutant RabG3b, respectively, are also used in characteristics analysis. Moreover, a BR-insensitive mutant bri1-301 including vascular deletion (Cano-Delgado, A., et al. (2004) Development, 131, 5341-5351) and autophagy mutant atg5-1 (Thompson, A. R., et al. (2005) Plant Physiol. 138, 2097-2110) were used. Growth phenotypes of plants were investigated under long-day conditions (16/8 h light/dark cycle) ( FIG. 1 ). As a dominant phenotype, a RabG3bCA plant has a stem growing more highly than other tested plants, and stem thickening increased by approximately 14%, compared to the WT plant ( FIGS. 1 b and c ). In contrast, it was shown that an atg5-1 plant was grown in length shorter than the WT plant, and a bri1-301 plant is severely reduced in size. For bolting, the number and bolting time of rosette leafs were determined. RabG3bCA plant has been bolted earlier than the other plants ( FIG. 14 ), but there was no considerable difference in the number of leafs from tested plants ( FIG. 15 ). These results show that the increased length of stem in the RabG3bCA plant is due to faster stem growth, rather than adjustment of blooming time. Then, the possible relationship between changes in vascular development and growth phenotypes was investigated through histological analysis of cross sections of inflorescence stems which are derived from three different positions of plants ( FIGS. 2 and 3 ). All the vascular phenotypes of plants appeared normal, whereas the number of xylem cells considerably increased in the middle and the basal regions of the RabG3bCA inflorescence stems, in comparison with the WT plant ( FIG. 2 ). Moreover, quantification of xylem cells, which are divided into two different types of metaxylem and protoxylem, indicated that the number of metaxylem cells was remarkably increased in vascular bundles of the RabG3bCA plant, compared to the WT plant ( FIGS. 3 , 4 , and 16 ). In contrast, the RabG3bDN, RabG3bRNAi, and atg5-1 plants showed a significant decrease in number of both protoxylem and metaxylem in the basal region of inflorescence stems. These results show that the increased stem growth is associated with increased xylem differentiation in the RabG3bCA plant. Moreover, a decrease in number of xylem cells in the atg5-1 plant suggests that ATG5 and ATG5-linked autophagy may be associated with xylem differentiation. Formation of a secondary cell wall that is an index of the xylem differentiation was examined in a cross section of the inflorescence stem using lignin staining ( FIG. 17 a - f ) with phloroglucinol-HCl and lignin autofluorescence ( FIG. 17 g - l ). Lignified cell walls are expanded in the RabG3bCA plant, in comparison with the WT plant, whereas they are somewhat decreased in thickness in the RabG3bDN, RabG3bRNAi, bri1-301, and atg5-1 plants. Localization of RabG3b in the inflorescence stems was investigated through immunogold electron microscopy using anti-RabG3b antibody ( FIG. 18 ). RabG3b protein was largely located in xylem. In a cortex cell, gold particles were found in several sites including protoplasm, vacuole and cell wall ( FIG. 18 e - h ), but in a xylem TE cell deficient in protoplasm contents, RabG3b immunity was observed only in the secondary cell wall ( FIG. 18 m - p ). TE Formation Increases in RabG3bCA-Cultured Cells During Xylem Differentiation. In order to define functions of RabG3b in the xylem differentiation, an in vitro xylem TE inducible system was developed to culture Arabidopsis -suspended cells. When the TE differentiation was induced by BL and H 3 BO 3 treatment, RabG3bCA cells largely underwent vacuole rupture and loss of cell contents 4 days after the TE induction ( FIG. 19 ). Then, in comparison with the WT plant, RabG3bCA cells were considerably more generated into TE ( FIG. 5 ). In contrast, few cells differentiated from TE-induced culture of RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 are not observed, compared to the WT plant. Robust lignin staining was additionally observed in the RabG3bCA cells ( FIG. 20 ). These results suggest that RabG3b plays a positive role in the TE differentiation and ATG5-mediated autophagy has a positive effect on the TE differentiation. Autophagy is Activated During TE Differentiation. In order to determine whether RabG3b regulates the TE differentiation in the autophagy using its functions, an autophagy procedure was examined during TE formation by staining autophagic vacuole/lysosome with an acidotropic dye such as LysoTracker Green (LTG) (Via, L. E., et al. (1998) J. Cell Sci. 111, 897-905) ( FIG. 6 ). Prior to TE induction, LTG-stained structures were not detected in the tested plants, except for the RabG3bCA cells showing some faintly stained spots ( FIG. 6 a - e ). BL and H 3 BO 3 treatment induced the formation of LTG-stained autophagic vacuole/lysosome-like structures in WT cells, and this structure is remarkably increased in the RabG3bCA cells ( FIG. 6 k - l ). Under the same inducing conditions, no LTG-stained structures were formed in the RabG3bDN, RabG3bRNAi, or atg5-1 cells ( FIG. 6 c - e, h - j and m - o ). From these results, it was revealed that the autophagy may occur during the TE differentiation, and be activated by GTP-binding of RabG3b. RabG3bCA Cells Have Many Autophagic Structures Accumulated During TE Differentiation. Transmission electron microscope (TEM) analysis was conducted during the TE differentiation in order to examine microstructural changes in cells and determine LTG staining results ( FIG. 7 ). Non-induced cells showed fewer morphological differences in the tested plants ( FIG. 7 a - e ). For the TE induction, disintegration of cell contents and vacuole rupture were observed in the WT cells 4 days after the BL/H 3 BO 3 treatment ( FIG. 7 f ). During this period, the WT cells show autophagic vacuole/lysosome-like structure including disintegrated cell components ( FIGS. 7 f and p ). A large number of autophagic vacuole/lysosome-like structures are accumulated in the RabG3bCA cells, resulting in rapid loss of cell organs and contents ( FIGS. 7 g and q ). After 7 days of the TE induction, the RabG3bCA cells were completely differentiated into mature TE cells. This is confirmed by accumulation of hollow protoplast and secondary cell walls ( FIG. 7 l ). Moreover, the WT cells have still proceeded into the last stage of the TE differentiation ( FIG. 7 k ). In contrast, no autophagic vacuole/lysosome-like structures and TE-related morphological changes were observed in the RabG3bDN, RabG3bRNAi, or atg5-1 cells during the TE inducement ( FIG. 7 h - j and m - o ). During the TE differentiation, the formation of autophagic structures was further investigated in the WT and RabG3bCA cells ( FIG. 8 a - h ). The WT cells showed preautophagosomal structures or phagophores ( FIG. 8 b ), and accompanied autophagic vacuole/lysosome-like structures ( FIGS. 8 c and d ). Although the similar autophagic structures were observed in the RabG3bCA cells, they were formed earlier cells and more affluent, compared to the WT cells ( FIG. 8 e - h ). A large number of phagophores including protoplast materials and cell organelles (i.e., mitochondria) were observed after 1 day of the BL/H 3 BO 3 treatment ( FIG. 8 e ), and accumulation of the autophagic vacuoles was observed in the treated RabG3bCA cells after 2 days. Moreover, the preautophagosomal structures is still expanded in the WT cells. Then, the present inventors further tested whether activation of autophagy in the RabG3bCA cells is observed under the nutrient deficiency as a general autophagy condition ( FIG. 8 i - p ). Similarly, both of the WT and RabG3bCA cells showed autophagic structures in response to sucrose starvation, and the autophagic structures are shown earlier cells and more affluent in the RabG3bCA cells, compared to the WT cells. Such results suggest that the RabG3b is a positive regulator for autophagy and RabG3b-activated autophagy induces the cell death, thus contributing to the TE differentiation. RabG3b is Localized in Autophagic Structures. For autophagic vacuole/lysosome structures, localization of RabG3b proteins was analyzed through immunogold EM using antisera against the autophagic vacuole marker protein ATG8e and RabG3b in the TE-induced WT and RabG3bCA cells. In both of the WT and RabG3bCA cells, the RabG3b proteins were co-localized with the ATG8e protein in the autophagic structures ( FIG. 9 a - d ). Moreover, a level of the ATG8e protein was increased in the RabG3bCA cells, compared to the WT cells, and mostly was associated with autophagic structures and more increased in the BL/H 3 BO 3 -treated RabG3bCA cells ( FIG. 9 e ). Expression Analysis of Autophagy- and Xylem Differentiation-Related Genes According to the microarray data using Genevestigator, more than 20 of 36 currently defined autophagy-related genes (ATGs) are up-regulated during PCD or BL/H 3 BO 3 treatment. Therefore, 13 ATG genes implicated in several stages of the autophagy were selected and their expression levels were examined during the TE differentiation. Among the tested ATG genes, 9 genes showed no remarkable increase (less than 2 times), but 4 ATG genes (ATG6, 8g, 18h, and VPS34) were up-regulated more than 2 times in the BL/H 3 BO 3 treatment. Such results support that the autophagy is associated with the TE differentiation ( FIG. 10 a ). Moreover, in the late stage of the TE differentiation, expression levels of specific two groups of genes were investigated: PCD-related gene (BFN1, XCP1, AtXyn3, and AtMC9) and secondary cell wall-related gene (IRX1, 3, 5, 12, FRA8, CcOAOMT, and 4CL1) ( FIGS. 21 and 22 ). Expression of vascular system-related transcription factor genes (AtHB8, AtHB15, PHB, PHV, REV, VND6, and VND7), which control the initial stage of the TE differentiation, were examined, as well as BR-related genes (BRI1, BRL1, 2, and 3) ( FIGS. 23 a and 24 a ). A large number of the tested genes were greatly increased in transcriptome level in response to the TE induction. Expression of the up-regulated ATGs (ATG 6, 8g, 18h, and VPS34) was compared to the WT, RabG3bCA, and atg5-1 cells during the TE induction, but there are no differences in expression of several cell strains ( FIG. 10 b ). Since a great increase in the ATG8e proteins was already observed in both of the untreated and BL/H 3 BO 3 -treated RabG3bCA cells ( FIG. 9 e ), the ATG8e expression was additionally determined in the WT, RabG3bCA, and atg5-1 cells ( FIG. 25 ). The level of ATG8e basal transcriptome showed higher in RabG3bCA cells, in comparison with WT cells. Expression of up-regulated PCD-related (AtMC9, XCP1, and BFN1), secondary cell wall-related (IRX1, 5, 12 and FRA8), vascular system-related transcription factors (AtHB8, REV, and VND7), and BR-related (BRL2 and BRL3) genes was examined in WT, RabG3bCA, and atg5-1 cells. The tested PCD- and secondary cell wall-related genes were more strongly expressed in the RabG3bCA cells during the TE differentiation, compared to the WT cells ( FIG. 11 ), which suggests that the PCD and secondary cell wall accumulation is up-regulated in the RabG3bCA cells. The expression of the vascular system-related transcription factors and BR-related genes showed no considerable difference in the tested cells ( FIGS. 23 b and 24 b ). Such results indicate that the functions of RabG3b are more important after TE differentiation than during the initial vascular development. BRIEF DESCRIPTION OF THE DRAWINGS The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawings will be provided by the Office upon request and payment of the necessary fee. The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which: FIG. 1 is a diagram illustrating phenotypes of WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants: ( a ) Growth phenotypes of WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. 6-week old plants are photographed. ( b ) Stem length of plants in ( a ). Asterisks denote significant differences from the WT. (t Test: *P<0.05; **P<0.01; n=10). This experiment is repeated three with similar results. ( c ) Stem thickness measured in a lower-end portion of inflorescence stem of the plant in ( a ). Asterisks denote significant differences from the WT. (t Test; *P<0.05; **P<0.01; n=10). This experiment is repeated three with similar results. FIG. 2 is a diagram illustrating vascular bundles of inflorescence stems developed in WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - r ) Resin-filled cross sections of end ( a - f ), middle ( g - l ) and basal ( m - r ) regions of the inflorescence stems of the WT, RabG3bCA (#4-2), RabG3bDN (#2-11), RabG3bRNAi (#1-2), atg5-1, and bri1-301 plants, which are 6-week-old, stained with Toluidine blue. Ic, interfascicular cambium; Pc, (pro) cambium; Ph, phloem; Xy, xylem; Pi, pith. Bar=50 μm in ( a - f ), 100 μm in ( g - r ). FIG. 3 is a diagram illustrating vascular patterns of inflorescence stems in WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - r ) Resin-filled cross sections of end ( a - f ), middle ( g - l ) and basal ( m - r ) regions of the inflorescence stems of the WT, RabG3bCA (#4-2), RabG3bDN (#2-11), RabG3bRNAi (#1-2), atg5-1, and bri1-301 plants, which are 6-week-old, stained with Toluidine blue. Ic, interfascicular cambium; Pc, (pro) cambium; Ph, phloem; Mx, metaxylem; Px, protoxylem; Pi, pith. Bar=20 μm in ( a - f ), 50 μm in ( g - r ) FIG. 4 is a diagram illustrating quantitative analysis of xylem cells in WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - c ) Quantification of the number of protoxylem and metalxylem cells, and the number of xylem cells bound thereto in end ( a ), middle ( b ) and basal ( c ) regions of inflorescence stems of the WT, RabG3bCA (#4-2), RabG3bDN (#2-11), RabG3bRNAi (#1-2), atg5-1, and bri1-301 plants, which are 6-week old. Asterisks denote significant differences from each WT cells (t Test; *P<0.05; **P<0.01;***P<0.001; n=10). FIG. 5 is a diagram illustrating TE differentiation of cells cultured in WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - f ) Microscopic images of cultured cells for the TE-differentiation. Mature TEs having specific patterns of secondary cell walls are represented as the asterisk. Bar=10 μm. ( g ) Quantitative analysis of TE formation. In ( a - f ), Toluidine blue-stained cultured cells are photographed and mature TEs are counted in the area of 200 μm 2 in which 300-500 cells are present. The results are represented by means±SE of three independent experiments. Asterisks denote significant differences from the WT (t test; *P<0.01). FIG. 6 is a diagram illustrating autophagy activation in culture cells in which TEs are being differentiated. ( a - o ) LTG staining of autophagic structures in cells cultured from WT, RabG3bCA (#4-2), RabG3bDN (#2-11), RabG3bRNAi (#1-2), atg5-1, and bri1-301 plants. After 0 ( a - e ), 2 ( f - j ), and 4 ( k - o ) days of BL/H 3 BO 3 treatment, cultured cells are stained with LGT. Green spots represent autophagic vacuole/lysosome structures. Bar=10 μm. FIG. 7 is a diagram illustrating TEM images of autophagic structures in culture cells in which TEs are being differentiated. ( a - o ) LTG staining of autophagic structures in cells cultured from WT, RabG3bCA (#4-2), RabG3bDN (#2-11), RabG3bRNAi (#1-2), atg5-1, and bri1-301 plants. After 0 ( a - e ), 2 ( f - j ), and 4 ( k - o ) days of BL/H 3 BO 3 treatment, cultured cells are stained with LGT. Green spots represent autophagic vacuole/lysosome structures. ( p, q ) images in boxes in ( f ) and ( g ) are enlarged in ( p ) and ( q ), respectively. Autophagic vacuole/lysosome-like structures are represented by the arrows. Bar=2 μm in ( a - o ) and 0.1 μm in ( p,q ) FIG. 8 is a diagram illustrating TEM images of autophagic structures in WT and RabG3bCA cells during TE differentiation and in response to sucrose starvation. ( a - d ) Effects of TE induction on formation of autophagic structures in WT cell. Collection of TEM images of protoplast of WT culture cells which are BL/H 3 BO 3 treated for 1 ( a ), 2 ( b ), and 4 ( c,d ) days ( e - h ) Effects of TE induction on formation of autophagic structures in RabG3bCA cells Collection of TEM images of protoplast of RabG3bCA culture cells which are BL/H 3 BO 3 -treated for 1 ( e ), 2 ( f ), and 4 ( g,h ) days ( i - l ) Effect of sucrose starvation on formation of autophagic structures in WT cell After 0 ( i ), 1 ( j ), and 2 ( k,l ) days of the sucrose starvation, collection of TEM images of protoplast of WT seedling ( m - p ) Effect of sucrose starvation on formation of autophagic structures in RabG3bCA cell After 0 ( m ), 1 ( n ), and 2 ( o,p ) days of the sucrose starvation, collection of TEM images of protoplast of RabG3bCA seedling M: Mitochondria; G: Golgi body; AL: Autophagic vacuole/lysosome-like structure; Arrow head: preautophagosomal structure/phagophore; Arrow: autophagosome. Bar=0.5 μm. FIG. 9 is a diagram illustrating co-localization of RabG3b and ATG8e in the autophagic structures. ( a - d ) Immunogold labeling for co-localization of RabG3b and ATG8e in culture cells treated with BL/H 3 BO 3 for 4 days. The arrow head and the arrow represent RabG3b (20-nm gold) and ATG8e (1-nm gold), respectively. Images in boxes in ( a ) and ( c ) are enlarged in ( b ) and ( d ), respectively. Bar=0.2 μm in ( a, c ) and 0.1 μm in ( b, d ) ( e ) Quantitative analysis of RabG3b and ATG8e proteins in WT and RabG3bCA culture cells which are untreated or treated with WBL/H 3 BO 3 for 4 days. RabG3b and ATG8e gold particles are counted in the area of 1.5 μm 2 of the TEM image, as shown in ( b ) and ( d ). The results are represented by means±SE of six independent experiments. Asterisks denote significant differences from each WT cell (t test; *P<0.05; **P<0.01;***P<0.001; n=10). FIG. 10 is a diagram illustrating expression analysis of autophagy-related genes during TE differentiation. ( a ) Relative expression of ATG gene in WT culture cells treated with BL/H 3 BO 3 ( b ) Relative expression of ATGs (ATG6, 8g, 18h, and VPS34) genes screened from WT, RabG3bCA, and atg5-1 culture cells which are treated with BL/H 3 BO 3 The results are represented by means±SE of three independent experiments. FIG. 11 is a diagram illustrating expression analysis of secondary cell wall-related gene and PCD-related gene during TE differentiation. ( a,b ) Relative expression of PCD-related genes (XCP1, AtMC9, and BFN1) ( a ) and secondary cell wall-related genes (IRX1, 5, 12, and FRA8) (b) screened from WT, RabG3bCA, and atg5-1 culture cells which are treated with BL/H 3 BO 3 . The results are represented by means±SE of three independent experiments. FIG. 12 is a diagram illustrating expression analysis of Arabidopsis RabG genes in EBL/H 3 BO 3 treatment. 1, RabG1 2, RabG2 3a, RabG3a 3b, RabG3b 3c, RabG3c 3d, RabG3d 3e, RabG3e 3f, RabG3f FIG. 13 is a diagram illustrating expression analysis of RabG3b in WT and two independent RabG3bRNAi cell lines. ( a ) RT-PCR analysis of a member of RabG3 gene family. Actin is used as the control. ( b ) Western blotting analysis of RabG3b protein. The total proteins are separated by SDS electrophoresis and Ponceau S staining (lower end) and Western blotting analysis (upper end) with anti-RabG3b antibody are conducted. FIG. 14 is a diagram illustrating a bolting time in WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. This experiment is repeated three with similar results (n=10). FIG. 15 is a diagram illustrating the total number of leaf in bolted WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. This experiment is repeated three with similar results (n=10). FIG. 16 is a diagram illustrating an example of cells counted from a cross section of an inflorescence stem of a RabG3bCA plant. Metaxylem and protoxylem cells are represented by pink and green, respectively. Bar=50 μm. FIG. 17 is a diagram illustrating development of xylem in WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - f ) Cross-sections of inflorescence stems of 6-week-old plants showing a lignified xylem cells stained with phloroglucinol-HCl. Bar=0.2 mm. ( g - l ) Cross-sections of inflorescence stems of 6-week-old plants showing lignified xylem cells identified by autofluorescence. Bar=20 μm. FIG. 18 is a diagram illustrating immunolocalization in inflorescence stem of the WT plant. In a lower-end portion of the inflorescence stem of the 6-week-old WT plant, the cross section is used for immunolocation of RabG3b protein. For a negative control, preimmune serum is used as the label. An arrow head represents gold particle integrated to RabG3b. CW: cell wall; V: vacuole. Bar=1 μm ( a - d ) and 0.2 μm ( e - p ). FIG. 19 is a diagram illustrating TE differentiation of cells cultured from WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - l ) Microscopic images of culture cells in which TEs are differentiated. The culture cells are stained with Toluidine blue after 0 ( a - f ) and 4 ( g - l ) days of BL/H 3 BO 3 treatment. Bar=10 μm. FIG. 20 is a diagram illustrating TE differentiation of cells cultured from WT, RabG3bCA, RabG3bDN, RabG3bRNAi, atg5-1, and bri1-301 plants. ( a - l ) TE lignified in culture cells. The culture cells are stained with phloroglucinol-HCl after 0 ( a - f ) and 7 days ( g - l ) of BL/H 3 BO 3 treatment. Bar=0.1 mm. FIG. 21 is a diagram illustrating expression analysis of secondary cell wall-related genes during TE differentiation. The results are represented by means±SE of three independent experiments. FIG. 22 is a diagram illustrating expression analysis of PCD-related genes during TE differentiation. The results are represented by means±SE of three independent experiments. FIG. 23 is a diagram illustrating expression analysis of vascular system-related transcription factors during TE differentiation. ( a ) Relative expression of vascular system-related transcription factors in WT culture cells treated with BL/H 3 BO 3 . ( b ) Relative expression of vascular system-related transcription factor genes (AtHB8, REV, and VND7) in WT, RabG3bCA, and atg5-1 culture cells which are treated with BL/H 3 BO 3 . The results are represented by means±SE of three independent experiments. FIG. 24 is a diagram illustrating expression analysis of BR-related genes during TE differentiation. ( a ) Relative expression of BR-related genes in WT culture cells which are treated with BL/H 3 BO 3 . ( b ) Relative expression of BR-related genes in WT, RabG3bCA, and atg5-1 culture cells which are treated with BL/H 3 BO 3 . The results are represented by means±SE of three independent experiments. FIG. 25 is a diagram illustrating expression analysis of ATG8e gene during TE differentiation. The total RNAs are extracted at given times from WT, RabG3bCA, and atg5-1 culture cells, which are treated with BL/H 3 BO 3 and are subjected to real-time qRT-PCR analysis. The results are represented by means±SE of three independent experiments. FIG. 26 is a diagram illustrating a cleavage map of an expression vector. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. Hereinafter, exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. However, preferred embodiments are described to illustrate the present invention, but the scope of the present invention is not limited to the embodiments disclosed hereinafter. Example 1 Plant Material and Growth Condition Arabidopsis thaliana plants were grown at 24° C. in a growth room under long-day conditions (16-h light/8-h dark cycle). Arabidopsis callus were formed from seed leaves of young seedlings in an induction medium (Murashige and Skoog [MS] medium, pH 5.8, 3% sucrose, 0.8% agar and 2 mg/l 2,4-dichlorophenoxyacetic acid (2,4-D)). A suspension cell culture was initiated by inoculating 1 to 2 g of callus into 50 ml of MS medium supplemented with 3% sucrose and 1 mg/l 2,4-D, and subcultured at 24° C. in a dark room while stirring. For the TE induction, the subcultured cells were transferred into a 2,4-D-free fresh medium containing 1 μM BL and 10 mM H 3 BO 3 . Aliquots were taken at given times for further analysis. In order to induce the sucrose starvation, 1-week-old seedlings grown on the MS (1% sucrose) medium were transferred to a MS medium without sucrose and further grown in a dark room. Plants were harvested 0, 1, and 2 days after their transfer (Contento et al., 2005). Example 2 Generation of RabG3b Knockdown Plants An Agrikola RNAi knockdown delivery clone (CATMA1a21795) of RabG3b was purchased from Nottingham Arabidopsis Stock Centre (NASC). The construct was transformed into Arabidopsis through vacuum infiltration using Agrobacterium tumefaciens strain GV3101 (Clough and Bent, 1998). Transformants (T 1 ) were screened based on BASTA resistance. T 3 homozygous lines were recovered and tested for reduction of RabG3b expression. Two independent lines (#1-2 and #3-16) were used for further analysis. Example 3 RNA Analysis Quantitative real-time RT-PCR was performed in a LightCycler 480 system (Roche) using a KAPA SYBR FAST qPCR master mix. PCR reaction was performed according to the manufacturer's protocol. The gene-specific primers used in the present invention are listed in the following Table 1. The expression of the tested genes was standardized to the constitutive expression level of UBQ5, and calculated using the 2 −ΔΔt method (Livak and Schmittgen, 2001). This experiment was repeated at least three times with biologically independent samples. TABLE 1 Accession Genes numbers Forward primers Reverse primers For RT-PCR RabG3a At4g09720 GATAAGAAAGCAGCTGACTGGTGT GATCATACACAGACTTCTCCAATC (SEQ ID NO: 4) (SEQ ID NO: 5) RabG3b At1g22740 AGAAGGCTAGAGAATGGTGTGCTGA CATACAAATCGTGAACCACCAAATG (SEQ ID NO: 6) (SEQ ID NO: 7) RabG3c At3g16100 AGATGGAGTCAATGTTGATGCAGCT GAAGATTACGACAAGCTGAAGAGAT (SEQ ID NO: 8) (SEQ ID NO: 9) RabG3d At1g52280 CGCCAAAGAAGGATTCAATGTAGA GAGTCCAAAAGAAAAAGGAACCCA (SEQ ID NO: 10) (SEQ ID NO: 11) Actin GGCGATGAAGCTCAATCCAAACG GGTCACGACCAGCAAGATCAAGACG (SEQ ID NO: 12) (SEQ ID NO: 13) For real-time qRT-PCR IRX1 At4g1g780 CATCCCAACGCTATCAAACCTA GCTGAGACACCTCCAATAACCC (SEQ ID NO: 14) (SEQ ID NO: 15) IRX3 At5g17420 TCGGTGGCATGATGAATTTG CACATCTATACCACTTCTTGCCTACTG (SEQ ID NO: 16) (SEQ ID NO: 17) IRX5 At5g44030 TCTGGGTGATTGGCGGTG GTCGGAGGGATGAGAAGGGT (SEQ ID NO: 18) (SEQ ID NO: 19) IRX12 At2g38030 CCTAAGGATCTTCCCAAGTGCTAA CTTGGACGTGGCGTGATGT (SEQ ID NO: 20) (SEQ ID NO: 21) VND6 At5g62380 GAAAATGGACCGCCTCATGA TCATCGTGGTTAGCTTCTTCTTGA (SEQ ID NO: 22) (SEQ ID NO: 23) VND7 At1g71930 TTCGAAACGCAGTCGTATAATCC ATTAGCTTCGACCTCATTATAGCTTTG (SEQ ID NO: 24) (SEQ ID NO: 25) XCP1 At4g35350 GTTGTGCTTTTGCCCGTGAT GAAGCTTGTCAGTGTTTGTCAAATG (SEQ ID NO: 26) (SEQ ID NO: 27) AtXyn3 At4g08160 CCACCTCCACGAGCTGACATTC AAGGAGGAGGCGATGGACGATTC (SEQ ID NO: 28) (SEQ ID NO: 29) AtMC9 At5g04200 AGGCAGTCCTTGACCACTTG CCCTGAGTCCACGTGTTTTT (SEQ ID NO: 30) (SEQ ID NO: 31) ATG1a Atlg49180 TGCCACACTGGGCATAGAAGAT TCCAGTTACACGAGCCATTTCA (SEQ ID NO: 32) (SEQ ID NO: 33) ATG1b At2g37840 ATTCTGAATCCGCCACTGTC GAGAACCCAACCCAAGTGAA (SEQ ID NO: 34) (SEQ ID NO: 35) ATG1c At3g53930 GAAATATCAGCCACGGAGGA GCACCGCTTTTGAGTAGAGG (SEQ ID NO: 36) (SEQ ID NO: 37) ATG1d At3g61960 GAAACAAGTGCTGCCACTCA AATCCGCTTCTTGTCGTCAG (SEQ ID NO: 38) (SEQ ID NO: 39) ATG5 At5g17290 TTAATCGCCCTGTTGAGTTCCTCA TACCACCCACGAAAACGGTATCTC (SEQ ID NO: 40) (SEQ ID NO: 41) ATG6 At3g61710 TTGCAAATTCAAAGGACCAAGAGA AGAGAGACCGTCGCAGAGAGAGGT (SEQ ID NO: 42) (SEQ ID NO: 43) ATG7 At5g45900 GTACCGCTTGCTCTGAAACC GTCTTCCCAGTCGAGGTTGA (SEQ ID NO: 44) (SEQ ID NO: 45) ATG8a At4g21980 GGAGAAGGCTGGACAAAGTGATGT TAGATCGCAGACATCAATGCAGCA (SEQ ID NO: 46) (SEQ ID NO: 47) ATG8e At5g05150 ACCCTGATCGAATTCCTGTGATTG AGCTCTCCTGTTGGAGGAAGAACA (SEQ ID NO: 48) (SEQ ID NO: 49) ATG8g At3g60640 ACCGGAGCGATGATGTCAACCATT TGCAAACCGATTGGTTGTGCCTAC (SEQ ID NO: 50) (SEQ ID NO: 51) ATG10 At3g07525 CCCAACCATGGAAAATGAAG GAACCATGGCCTGTTCAAAT (SEQ ID NO: 52) (SEQ ID NO: 53) ATG12a At1g54210 GCATGGGGCTAAAACTGAAG GCCGACGGAAAAATACAAAG (SEQ ID NO: 54) (SEQ ID NO: 55) ATG18b At4g30510 TTTGGACCATCGACACAGCTTCCA ACTGCGTTTTGAAGCACATGATGA (SEQ ID NO: 56) (SEQ ID NO: 57) ATG18d At3g56440 TGACCTTGACATTGGATGGCTTGC TTGATACTGCAAGCCACTGCACGT (SEQ ID NO: 58) (SEQ ID NO: 59) ATG18h At1g54710 ACGCTCATGTCTTGCCAAAGAACG TTTCATTGGAGACCACCTCCTCGA (SEQ ID NO: 60) (SEQ ID NO: 61) VPS34 At1g60490 AGACACCTGGACAACCTCCTCCTT GGAATAGTTGAACCCGCCATGAGA (SEQ ID NO: 62) (SEQ ID NO: 63) AtTOR At1g50030 TGAAGTCCCCCAATTAGCAC ACGGCACGCTCATTTAAAAC (SEQ ID NO: 64) (SEQ ID NO: 65) BRI1 At4g39400 GATTCACCGGATTTTGGAGA GACCCGGCTTGTATCTCCTT (SEQ ID NO: 66) (SEQ ID NO: 67) BRL1 At1g55610 TTGATCCGGAGCTTGTAACC CCTTATCTCGCGATTCTTCG (SEQ ID NO: 68) (SEQ ID NO: 69) BRL2 At2g01950 CGAGACTGATCAGCGCATTA TTTCCCTTCTCTTGCCTTCA (SEQ ID NO: 70) (SEQ ID NO: 71) BRL3 At3g13380 GAGCTCCTCTCAGGCAAGAA CGATCGTCCAAACATTGAGA (SEQ ID NO: 72) (SEQ ID NO: 73) AtHB8 At4g32880 AATCATTCCTTCCGGTTTCC CGACGCGATCACACTTCTTA (SEQ ID NO: 74) (SEQ ID NO: 75) AtHB15 Atlg52150 GCGGGATATGTCTCTCAAGC TACAGCCAAAAGGCAAAAGC (SEQ ID NO: 76) (SEQ ID NO: 77) PHB At2g34710 GCTTCACCGGTTTTCACATT AGAACTTTCCACACCGTTGC (SEQ ID NO: 78) (SEQ ID NO: 79) PHV At1g30490 CTTCCGGCAGGAATATGTGT GCCAAAAACAACATCCCCTA (SEQ ID NO: 80) (SEQ ID NO: 81) REV At5g60690 ATTCACTTGGAAGCGACGAC GCGAAGTCCGAACAGATAGC (SEQ ID NO: 82) (SEQ ID NO: 83) FRA8 At2g28110 GACTTGTTGAATCGGTGGCTC GAAAGAGTTTGACCTTCTAAC (SEQ ID NO: 84) (SEQ ID NO: 85) CCoAOMT At4g34050 TCGTTGATGCTGACAAAGACA ACTGATGCGACGGCAGATAG (SEQ ID NO: 86) (SEQ ID NO: 87) 4CL1 At1g51680 GGTTACCTCAACAATCCGGCA CAAATGCAACAGGAACTTCAC (SEQ ID NO: 88) (SEQ ID NO: 89) BFN1 At1g11190 CGTGGACAGAATGCAACGATC ACCAGCAATAGCATGATCGTC (SEQ ID NO: 90) (SEQ ID NO: 91) UBQ5 At3g62250 GACGCTTCATCTCGTCC GTAAACGTAGGTGAGTCCA (SEQ ID NO: 92) (SEQ ID NO: 93) Example 4 Histochemical Analysis Plant samples (cultured cells and inflorescence stems of 7-week-old plants) were fixed at 4° C. for 4 hours in a solution containing 2.5% glutaraldehyde and 4% para-formaldehyde in 0.1 M phosphate buffer (pH 7.4), rinsed in 0.1 M phosphate buffer (pH 7.4), and further fixed at room temperature for 2 hours in 1% OsO 4 . After rinsing in the 0.1M phosphate buffer, the resulting samples were dehydrated and embedded in a LR white resin (London Resin). Cross-sections (1 μm) were prepared using an ultramicrotome (RMC MT X) and stained briefly with filtered 1% Toluidine blue. These sections were photographed using a light microscope (Olympus, BX51TRF), and images were used to measure stem thickness and count protoxylem and metaxylem cells within vascular bundles (n=10). For TEM analysis, thinner sections (60-70 nm thickness) were collected on copper grids (1-GN, 150 mesh), stained with uranyl acetate and lead citrate, and examined by TEM (Philips, Tecnai 12). For immunolocalization, the sections collected on the nickel grids were blocked for 1 hour with a BSA-TBS buffer (500 mM NaCl, 1% BSA, 0.3% Tween 20, and 10 mM Tris-HCl, pH 7.4). The sections were then incubated with anti-RabG3b antiserum (rabbit) and/or anti-ATG8e antiserum (rat) for 4 hours at room temperature. After rinsing in the BSA-TBS buffer, binding of the primary antibody was detected using anti-rabbit IgG (20-nm gold, Electron Microscopy Sciences) and anti-rat IgG (1-nm gold, Sigma). After washing in the BSA-TBS and deionized water, the resulting samples were stained with uranyl acetate before TEM analysis. Example 5 Lignin Staining Lignin staining was performed in the same manner as described in the previous studies (see: Protoplasma 220, 17-28, Pomar et al., 2002). In order to stain the inflorescence stems, cross-sections from the middle region of the inflorescence stems from the 6-week-old plants were prepared by cutting the middle region with a razor blade. The sections and cultured cells were then stained in a phloroglucinol solution (2% ethanol/water, 95/5 (v/v)) for 1 minute and soaked in 6 N HCl. Bright field photographs of the stained inflorescence stem samples and the cell culture samples were collected using a binocular microscope (Leica EZ4D) and a light microscope (Olympus, BX51TRF), respectively. Autofluorescence of lignin was detected using a confocal microscope (Zeiss LSM 510 META) as excited/emitted at 420/480 nm. Example 6 LTG Staining LTG staining was performed in the same manner as described in the previous studies (see: Cell, 121, 567-577, Liu et al., 2005). Cultured cells were incubated for 1 hour with 1 μM LTG DND-26 (Molecular Probes) in a dark room. Images were obtained using a confocal microscope (Zeiss LSM 510 META) as excited/emitted at 488/505 nm. As seen according to the present invention, when the RabG3b genes according to the present invention are overexpressed, the promotion of biomass was observed, in comparison with the wild type. As seen from these effects, it was revealed that, in the RabG3bCA cells, a small GTP binding protein RabG3b continue to activate the autophagy and this activation of the autophagy is performed through accumulation of a large number of autophagic vacuoles and lysosomes. While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations may be made without departing from the scope of the invention as defined by the appended claims.
There are provided a method for promoting plant biomass by overexpression of a gene coding a small GTP binding protein RabG3b or mutants thereof, a vector including the gene, a transgenic plant comprising the expression vector and a method for preparing the transgenic plant.
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BACKGROUND OF THE INVENTION [0001] This invention relates to an electroless gold method and also to electronic parts that are electrolessly gold plated by the method. [0002] Hitherto, electroless nickel/immersion gold platings have been in frequent use for surface treatment for applications that require high reliability in mounting processes of printed circuit boards or electronic parts. In the immersion gold plating, gold is deposited by using a difference in redox potential between an underlying nickel layer and a plating bath, so that gold dissolves the nickel thereby corroding the nickel. In addition, diffusion of nickel over the gold film takes place, thereby lowering wire bondability. To avoid this, reduction gold plating is further performed on the electroless nickel/immersion gold plating films to make a thick gold film thereby suppressing the wire bondability from lowering, but with a problem of costs. [0003] On the other hand, according to the recent lead-free promotion, there is a trend toward the use of Sn—Ag—Cu solder. However, a greater thermal load is needed upon solder bonding when compared with conventional tin-lead eutectic solders, with the attendant problem that bonding characteristics lower. To cope with this, there has been recently carried out a method of avoiding the above problem wherein a palladium film is sandwiched between the electroless nickel plating layer and the immersion gold plating layer according to electroless palladium plating. [0004] It will be noted that mention is made, as related art technical literatures, of Japanese Patent Laid-open No. Hei 10-242205, Japanese Patent No. 3565302, Japanese Patent No. 3596335, Japanese Patent No. 3345529, Japanese Patent Laid-open No. 2004-332025, Japanese Patent Laid-open No. 2002-118134, Japanese Patent Laid-open No. 2006-339609 and Japanese Patent Laid-open No. Hei 8-269726. SUMMARY OF THE INVENTION [0005] With a surface treatment for the purpose of solder bonding, a gold film on a palladium film may be thinly plated at about 0.05 μm (by flash gold plating). When the gold plating film is too thick, alloy formation of tin and nickel does not become uniform, with concern that solder bondability lowers. With a surface treatment for the purpose of solder bonding, it is usual from the standpoint of costs that a thickness capable of imparting the rust-proof function of an underlying metal is at about 0.05 μm. [0006] With a surface treatment for the purpose of wire bonding, a gold film on a palladium film should have a thickness of 0.2 μm or over. Until now, after thin coating by immersion gold plating (flash gold plating), thick coating by reduction gold plating is carried out. Wire bondability is more advantageous when the gold film is thicker. This is because a thicker gold film is more capable of suppressing underlying nickel from being diffused and, at the same time, results in higher bonding strength. [0007] Where solder bonding and wire bonding are both carried out with respect to the same substrate, e.g. where a substrate is subjected to different treatments in a next step on opposite surfaces thereof (e.g. wire bonding on a front surface and solder bonding on a back surface), the thickness of the gold film on the palladium film is set at about 0.2 to 0.3 μm. A thick gold film is better for wire bonding and a thin gold film is better for solder bondability. Although an optimum thickness changes depending on the requirement for a higher characteristic as to whichever of wire bonding or solder bonding, it is considered that about 0.2 to 0.3 μm is optimal as a thickness at which both bondings are mutually balanced. [0008] Conventionally, when a gold plating film is formed on a palladium film in a certain thickness (especially, in 0.15 μm or over), gold is once thin-plated by immersion gold plating (flash gold plating) on the palladium film because direct thick coating or plating on the palladium film by reduction gold plating is not possible. Thereafter, it is needed to increase the thickness by reduction gold plating. It is almost difficult to form a gold plating film with a thickness of not smaller than 0.15 μm by immersion gold plating. On the other hand, when the gold plating film is thickened by direct reduction gold plating, the thickness of the gold film varies. Accordingly, characteristics necessary for the wire bonding or solder bonding are not obtained. [0009] Under these circumstances in the art, the invention has for its object the provision of a method wherein an electroless gold plating film of a plated film laminate formed of an electroless nickel plating film, an electroless palladium plating film and an electroless gold plating film can be efficiently formed. [0010] We made intensive studies so as to solve the above problems and, as a result, found that where a plated film laminate is formed of an electroless nickel plating film, an electroless palladium plating film and an electroless gold plating film, the electroless gold plating film is formed by electroless gold plating using a gold plating bath including a water-soluble gold compound, a complexing agent, formaldehyde and/or a formaldehyde bisulfite adduct, and an amine compound represented by the following general formula (1) or (2) [0000] R 1 —NH—C 2 H 4 —NH—R 2   (1) [0000] R 3 —(CH 2 —NH—C 2 H 4 —NH—CH 2 ) n —R 4   (2) [0000] (in the formulae (1) and (2), R 1 , R 2 , R 3 and R 4 represent —OH, —CH 3 , —CH 2 OH, —C 2 H 4 OH, —CH 2 N(CH 3 ) 2 , —CH 2 NH(CH 2 OH), —CH 2 NH(C 2 H 4 OH), —C 2 H 4 NH(CH 2 OH), —C 2 H 4 NH(C 2 H 4 OH), —CH 2 N(CH 2 OH) 2 , —CH 2 N(C 2 H 4 OH) 2 , —C 2 H 4 N(CH 2 OH) 2 or —C 2 H 4 N(C 2 H 4 OH) 2 and may be the same or different and n is an integer of 1 to 4). In doing so, the electroless gold plating film can be efficiently formed by use of one kind of plating bath for different thicknesses adapted for solder bonding or wire bonding. Especially, an electroless gold plating film, which is suited for solder bonding and wire bonding or suited for wire bonding and has a thickness of not smaller than 0.15 μm, can be efficiently, effectively formed by one step using one kind of plating bath, thus arriving at completion of the invention. [0011] More particularly, the invention provides, as a first invention, [0000] [1] a method for forming a plated film laminate obtained by forming, on a surface to be plated of an electronic part such as a printed circuit board, a ceramic substrate or a semiconductor substrate, a 0.1 to 20 μm thick of electroless nickel plating film through a catalyst, further forming a 0.001 to 0.3 μm thick of electroless palladium plating film on the electroless nickel plating film, and still further forming an electroless 0.01 to 1.0 μm thick of electroless gold plating film on the electroless palladium plating film, characterized in that part or whole of the electroless gold plating film of the plated film laminate is formed by a first electroless gold plating using a first electroless gold plating bath including a water-soluble gold compound, a complexing agent, formaldehyde and/or a formaldehyde bisulfite adduct, and an amine compound represented by the following general formula (1) or (2) [0000] R 1 —NH—C 2 H 4 —NH—R 2   (1) [0000] R 3 —(CH 2 —NH—C 2 H 4 —NH—CH 2 ) n —R 4   (2) [0000] (in the formulae (1) and (2), R 1 , R 2 , R 3 and R 4 represent —OH, —CH 3 , —CH 2 OH, —C 2 H 4 OH, —CH 2 N(CH 3 ) 2 , —CH 2 NH(CH 2 OH), —CH 2 NH(C 2 H 4 OH), —C 2 H 4 NH(CH 2 OH), —C 2 H 4 NH(C 2 H 4 OH), —CH 2 N(CH 2 OH) 2 , —CH 2 N(C 2 H 4 OH) 2 , —C 2 H 4 N(CH 2 OH) 2 or —C 2 H 4 N(C 2 H 4 OH) 2 and may be the same or different and n is an integer of 1 to 4). [2] In this method, it is preferred that the electroless gold plating film is wholly formed in a thickness of not smaller than 0.15 μm only by the first electroless gold plating. [3] It is also preferred that part of the electroless gold plating film is formed by the electroless gold plating using the first electroless gold plating bath and the balance of the electroless gold plating film is formed by a second electroless gold plating using a second reduction gold plating bath different from the first electroless gold plating bath. [0012] Especially, the methods of [1] to [3] are suited for the case where the surface of the electroless gold plating film is provided as a face to be solder bonded. The methods of [2] and [3] are suited for the case where the surface of the electroless gold plating film is provided as a face to be wire bonded. [0013] Further, the invention provides, as a second invention, an electronic part such as a printed circuit board, a ceramic substrate or a semiconductor substrate which has, on a surface thereof to be plated, a plated film laminate obtained by forming a 0.1 to 20 μm of thick electroless nickel plating film through a catalyst, further forming a 0.001 to 0.3 μm thick of electroless palladium plating film on the electroless nickel plating film, and still further forming an electroless 0.01 to 1.0 μm thick of electroless gold plating film on the electroless palladium plating film, characterized in that part or whole of the electroless gold plating film is formed by a first electroless gold plating using a first electroless gold plating bath including a water-soluble gold compound, a complexing agent, formaldehyde and/or a formaldehyde bisulfite adduct, and an amine compound represented by the following general formula (1) or (2) [0000] R 1 —NH—C 2 H 4 —NH—R 2   (1) [0000] R 3 —(CH 2 —NH—C 2 H 4 —NH—CH 2 ) n —R 4   (2) [0000] (in the formula (1) or (2), R 1 , R 2 , R 3 and R 4 represent —OH, —CH 3 , —CH 2 OH, —C 2 H 4 OH, —CH 2 N(CH 3 ) 2 , —CH 2 NH(CH 2 OH), —CH 2 NH(C 2 H 4 OH), —C 2 H 4 NH(CH 2 OH), —C 2 H 4 NH(C 2 H 4 OH), —CH 2 N(CH 2 OH) 2 , —CH 2 N(C 2 H 4 OH) 2 , —C 2 H 4 N(CH 2 OH) 2 or —C 2 H 4 N(C 2 H 4 OH) 2 and may be the same or different and n is an integer of 1 to 4). [0014] The method of the invention does not need to provide two types of baths, a flash gold plating bath and a thick gold plating bath for thickening, but one type of gold plating bath enables gold plating films of different thicknesses suited for solder bonding or wire bonding to be formed. Especially, because an electroless gold plating film with a thickness of not smaller than 0.15 μm can be formed using one kind of plating bath by one step in an efficient, effective manner, simplification of the procedure is possible with the attendant advantage in costs. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0015] The electroless gold plating method of the invention is directed to the formation of an electroless gold plating film of a plated film laminate, which is obtained by forming, on a surface of an electronic part to be plated, a 0.1 to 20 μm thick of electroless nickel plating film through a catalyst, further forming a 0.001 to 0.3 μm thick of electroless palladium plating film on the electroless nickel plating film, and still further forming a 0.01 to 1.0 μm thick of electroless gold plating film. [0016] In the practice of the invention, the formation of the catalytic electroless nickel plating film and the electroless palladium plating film of the plated film laminate can be carried out by application of conventional, known techniques, and the electroless gold plating method of the invention is applicable as so-called ENEPIG (Electroless Nickel Electroless Palladium Immersion Gold), i.e. as a method for forming a gold plating film on an underlying electroless nickel plating film (formed on copper) through an electroless palladium plating film. [0017] When the electroless nickel plating film is formed on a surface to be plated (e.g. a surface of a copper substrate) through a catalyst, a metal serving as the catalyst includes nickel, cobalt, iron, silver, gold, ruthenium, palladium, platinum or the like, of which palladium is preferred. The deposition amount of the catalyst may be one sufficient for activation to an extent that an electroless nickel film is deposited on the surface to be plated. When an amount of deposition is at not smaller than 0.1×10 −4 mg/dm 2 , preferably not smaller than 1×10 −4 mg/dm 2 , the resulting film may not be continuous. [0018] Although the electroless nickel plating film formed has no limitation with respect to the type of plating bath, the electroless nickel plating film is preferably one that is formed by a plating bath described in Japanese Patent laid-open No. Hei 8-269726. This electroless nickel plating bath is characterized by adding a compound having an S—S bond to a plating bath containing a water-soluble nickel salt, a reducing agent and a complexing agent. [0019] The water-soluble salt used includes nickel sulfate, nickel chloride or the like and is preferably used in an amount of 0.01 to 1 mol/liter, more preferably 0.05 to 0.2 mols/liter. The reducing agent includes a hypophosphorous acid such as hypophosphite, sodium hypophosphite or the like, dimethylamine borane, trimethylamine borane, hydrazine or the like. The amount of the reducing agent is preferably in the range of from 0.01 to 1 mol/liter, more preferably from 0.05 to 0.5 mols/liter. [0020] The complexing agent includes a carboxylic acid such as malic acid, succinic acid, lactic acid, citric acid or the like and a sodium salt thereof, or an amino acid such as glycine, alanine, iminodiacetic acid, arginine or glutamic acid. The amount is preferably in the range of from 0.01 to 2 mols/liter, more preferably from 0.05 to 1 mol/liter. [0021] Although the S—S sulfur bond-containing compounds may be organic sulfur compounds, inorganic sulfur compounds such as thiosulfates, dithionates, polythionates (e.g. O 3 S—S n —SO 3 wherein n=1 to 4) and dithionites are preferably mentioned. It will be noted that salts used are water-soluble salts such as sodium salts and the like. The amount of the sulfur bond-containing compound is preferably in the range of from 0.01 to 100 mg/liter, more preferably from 0.05 to 50 mg/liter. When the amount is smaller than 0.01 mg/liter, the above-stated object of the invention cannot be achieved satisfactorily. Over 100 mg/liter, there occurs a phenomenon wherein no plating film is deposited at all. [0022] The electroless nickel plating solution may be further admixed with a water-soluble lead salt such as lead acetate or a sulfur compound such as thioglycolic acid generally used as a stabilizing agent. The amount is preferably in the range from 0.1 to 100 mg/liter. The pH of the electroless nickel plating solution ranges from 4 to 7, preferably from 4 to 6. [0023] When a nickel film is formed by use of the above plating bath, the deposition rate of nickel is improved, deposition at the outside of a pattern is suppressed, and the deposition rate of palladium is prevented from lowering. Where the electroless nickel plating film is made of a Ni—P alloy film, the content of P in the film is preferably from 3 to 10 wt %. Outside the above range, there is concern that solder bondability and wire bondability lower. [0024] The electroless nickel plating film formed should preferably have a thickness of from 0.1 to 20 μm, more preferably from 1 to 15 μm. When the thickness is smaller than 0.1 μm, there is concern that wire bondability lowers. Over 20 μm, it takes a long plating time, with the possibility that productivity becomes worsened, thus being disadvantageous in cost. [0025] On the other hand, the electroless palladium plating film formed has no limitation with respect to the type of plating bath such as a immersion type, a reduction type (a formic acid bath, a hypophosphite bath, or a phosphite bath) or the like. It is preferred to form a plating film in an electroless palladium plating bath, which is characterized by including, for example, a palladium compound, at least one compound selected from ammonia and amine compounds for use as a complexing agent, at least one hypophosphorous acid compound selected from hypophosphorous acid and hypophosphites for use as a reducing agent, and at least one unsaturated carboxylic acid compound selected from unsaturated carboxylic acids, unsaturated carboxylic anhydrides, unsaturated carboxylic acid salts and unsaturated carboxylic acid derivatives. [0026] The palladium compound may be any of those compounds that are soluble in water and include, for example, palladium chloride, palladium sulfate, palladium acetate, palladium nitrate, tetraamine palladium chloride and the like. The amount is preferably in the range from 0.001 to 0.5 mols/liter, more preferably from 0.005 to 0.1 mol/liter calculated as palladium. Smaller amounts result in the lowering of a plating rate and larger amounts may lower physical properties of the film. [0027] At least one member selected from hypophosphorous acid and hypophosphites is contained as a reducing agent. The amount is preferably in the range from 0.001 to 5 mols/liter, more preferably from 0.2 to 2 mols/liter. Smaller amounts lower the deposition rate and larger amounts may instabilize the bath. As a hypophosphite, mention is made of sodium hypophosphite, ammonium hypophosphite and the like. [0028] At least one member selected from ammonia and amine compounds is further contained as a complexing agent. The amount is preferably in the range of from 0.001 to 10 mols/liter, more preferably from 0.1 to 2 mols/liter. Smaller amounts lower the bath stability and larger amounts lower the plating rate. The amine compounds include methylamine, dimethylamine, trimethylamine, benzylamine, methylenediamine, ethylenediamine, tetramethylenediamine, diethylenetriamine, EDTA, sodium EDTA, potassium EDTA, glycine and the like. These may be used singly or in combination of two or more. [0029] The electroless palladium plating bath includes, aside from those components set out above, at least one unsaturated carboxylic acid compound selected from unsaturated carboxylic acids, unsaturated carboxylic anhydrides, unsaturated carboxylic acid salts, and unsaturated carboxylic acid derivatives. Specific examples of the unsaturated carboxylic acid include acrylic acid, propiolic acid, crotonic acid, iso-crotonic acid, methacrylic acid, maleic acid, fumaric acid, citraconic acid, trans-2-butene-1,2-dicarboxylic acid, itaconic acid, tetrolic acid, aconitic acid, muconic acid, sorbic acid, tiglic acid, angelic acid, senecioic acid, glutaconic acid, mesaconic acid, oleic acid, linoleic acid, cinnamic acid and the like. The unsaturated carboxylic acid anhydrides and unsaturated carboxylic acid salts include anhydrides, sodium salts, ammonium salts and the like of those unsaturated carboxylic acids indicated above. Moreover, mention is made, as an unsaturated carboxylic acid derivative, of ethyl methacrylate, phenyl methacrylate, isobutyl acrylate, methyl propiolate, maleic hydrazide and the like. These unsaturated carboxylic acids, unsaturated carboxylic anhydrides, unsaturated carboxylic acid salts and unsaturated carboxylic acid derivatives may be used singly or in combination of two or more. [0030] Especially, preferable unsaturated carboxylic acids, unsaturated carboxylic anhydrides, unsaturated carboxylic acid salts and unsaturated carboxylic acid derivatives include acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid and mesaconic acid, and anhydrides, salts and derivatives thereof. When using these unsaturated carboxylic acid compounds, the bath is excellent in stability and there can be obtained a palladium film that is excellent in solder bondability and wire bondability. [0031] The amount of an unsaturated carboxylic acid compound ranges preferably from 0.001 to 10 mols/liter, more preferably from 0.01 to 0.5 mols/liter. When the amount is smaller, an effect on the bath stability cannot be fully achieved. In contract, when the amount is larger, there is a tendency toward the lowering of plating rate. [0032] The electroless palladium plating bath has preferably a pH of from 4 to 10, more preferably from 6 to 8. A lower pH decreases the stability of plating bath and a higher pH increases a plating rate, with the tendency toward the deterioration of solder bonding and wire bonding characteristics. [0033] The thickness of the electroless palladium plating film is preferably in the range from 0.001 to 1.0 μm, more preferably from 0.01 to 0.3 μm. When the thickness is smaller than 0.001 μm, there is concern that wire bondability lowers. Over 1.0 μm, solder bondability may lower with a disadvantage in cost. [0034] In the practice of the invention, part or whole of the electroless gold plating film is formed according to the first electroless gold plating using an electroless gold plating bath comprising a water-soluble gold compound, a complexing agent, formaldehyde and/or a formaldehyde bisulfite adduct and an amine compound represented by the following general formula (1) or (2) [0000] R 1 —NH—C 2 H 4 —NH—R 2   (1) [0000] R 3 —(CH 2 —NH—C 2 H 4 —NH—CH 2 ) n —R 4   (2) [0000] (in the formula (1) or (2), R 1 , R 2 , R 3 and R 4 represent —OH, —CH 3 , —CH 2 OH, —C 2 H 4 OH, —CH 2 N(CH 3 ) 2 , —CH 2 NH(CH 2 OH), —CH 2 NH(C 2 H 4 OH), —C 2 H 4 NH(CH 2 OH), —C 2 H 4 NH(C 2 H 4 OH), —CH 2 N(CH 2 OH) 2 , —CH 2 N(C 2 H 4 OH) 2 , —C 2 H 4 N(CH 2 OH) 2 or —C 2 H 4 N(C 2 H 4 OH) 2 and may be the same or different and n is an integer of 1 to 4). [0035] Unlike a conventional immersion gold plating bath, the electroless gold plating bath of the invention is an electroless gold plating bath of the substitution-reduction type wherein both substitution reaction and reduction reaction proceed in the same plating bath. Since formaldehyde and/or a formaldehyde bisulfite adduct and the amine compound represented by the general formula (1) or (2) and having a specific type of structure are contained in the gold plating bath, the electroless gold plating bath of the invention allows not only gold to be deposited on an underlying metal by the substitution reaction, but also gold to be further deposited by means of a reducing agent through the initially deposited gold as a catalyst. [0036] When palladium is used as an underlying layer, a difference in potential between the palladium and gold is small. In this condition, when gold plating is carried out on palladium by use of a conventional immersion gold plating bath, a uniform film thickness cannot be obtained and a satisfactory film thickness is not ensured. In contrast, the electroless gold plating bath of the invention allows a palladium surface to be activated and gold to be deposited by means of a reducing agent while using the palladium as a catalyst. Gold can be further deposited using the once deposited gold as a catalyst, so that the gold plating film can be thickened on the palladium. Accordingly, in the practice of the invention, the whole of the electroless-gold plating film can be made as thick as 0.15 μm or over (not larger than 1.0 μm), particularly, not smaller than 0.2 μm that is suited for the case where the surface of the electroless gold plating film is provided as a wire bonding face, according only to the first electroless gold plating alone. Especially, the invention is suited for the formation of a 0.2 to 0.3 μm thick of film which is favorable for use as both a solder bonding face and a wire bonding face. [0037] The water-soluble gold compounds contained in the electroless gold plating bath of the invention include gold cyanide salts such as gold cyanide, gold potassium cyanide, gold sodium cyanide, gold ammonium cyanide and the like, and sulfites, thiosulfates, thiocyanates, sulfates, nitrates, methanesulfonates, tetrammine complexes, chlorides, bromides, iodides, hydroxides, oxides and the like of gold. Of these, gold cyanide salts are preferred. [0038] The content of the water-soluble gold compound is preferably in the range from 0.0001 to 1 mol/liter, more preferably from 0.002 to 0.03 mols/liter, calculated as gold. When the content is less than the above range, there is concern that the deposition rate lowers. Over the above range, an economical disadvantage may result in some case. [0039] The complexing agent contained in the electroless gold plating bath of the invention may be known ones ordinarily employed in electroless plating baths. Mention is made, for example, of phosphoric acid, boric acid, citric acid, gluconic acid, tartaric acid, lactic acid, malic acid, enthylenediamine, triethanolamine, ethylenediamine tetraacetic acid, nitrilotriacetic acid, diethylenetriamine pentaacetic acid, hydroxyethylethylenediamine triacetic acid, triethylenetetramine hexaacetic acid, 1,3-propanediamine tetraacetic acid, 1,3-diamino-2-hydroxypropane tetraacetic acid, hydroxyethylimino diacetic acid, dihydroxyl glycine, glycol ether diamine tetraacetic acid, dicarboxymethyl glutamic acid, hydroxyethylidene diphosphoric acid, ethylenediamine tetra(methylenephosphoric acid), alkali metal (e.g. sodium or potassium) salts, alkaline earth metal salts and ammonium salts thereof. [0040] The concentration of the complexing agent preferably ranges from 0.001 to 1 mol/liter, more preferably from 0.01 to 0.5 mols/liter. When the concentration is smaller than the above range, there is concern that the deposition rate lowers due to the metal dissolved out. Over the above range, an economical disadvantage may result in some case. [0041] The electroless gold plating bath of the invention contains formaldehyde and/or a formaldehyde bisulfite adduct therein. Specific examples of the formaldehyde bisulfite adduct include sodium formaldehyde bisulfite, potassium formaldehyde bisulfite, ammonium formaldehyde bisulfite and the like. [0042] The concentration of the formaldehyde and/or formaldehyde bisulfate adduct is preferably in the range of 0.0001 to 0.5 mols/liter, more preferably from 0.001 to 0.3 mols/liter. When the concentration is smaller than the above range, there is concern that the underlying nickel is corroded. Over the above range, there is concern for the instability of the bath. [0043] The electroless gold plating bath of the invention contains an amine compound represented by the following general formula (1) or (2) [0000] R 1 —NH—C 2 H 4 —NH—R 2   (1) [0000] R 3 —(CH 2 —NH—C 2 H 4 —NH—CH 2 ) n —R 4   (2) [0000] (in the formulae (1) and (2), R 1 , R 2 , R 3 and R 4 represent —OH, —CH 3 , —CH 2 OH, —C 2 H 4 OH, —CH 2 N(CH 3 ) 2 , —CH 2 NH(CH 2 OH), —CH 2 NH(C 2 H 4 OH), —C 2 H 4 NH(CH 2 OH), —C 2 H 4 NH(C 2 H 4 OH), —CH 2 N(CH 2 OH) 2 , —CH 2 N(C 2 H 4 OH) 2 , —C 2 H 4 N(CH 2 OH) 2 or —C 2 H 4 N(C 2 H 4 OH) 2 and may be the same or different and n is an integer of 1 to 4). [0044] The formaldehyde and/or formaldehyde bisulfite adduct does not act as a reducing agent when used alone, but develops the reduction action in coexistence with the amine compound. [0045] The concentration of these amine compounds is preferably in the range of from 0.001 to 3 mols/liter, more preferably from 0.01 to 1 mol/liter. When the concentration is smaller than the above range, there is concern that the deposition rate lowers. Over the above range, there is concern that the bath becomes instabilized. [0046] It will be noted that the molar ratio between the formaldehyde and/or formaldehyde bisulfite adduct and the amine compound is preferably such that formaldehyde and/or formaldehyde bisulfite adduct:amine compound=1:30 to 3:1, more preferably 1:10 to 1:1. When the ratio of the formaldehyde and/or formaldehyde bisulfite adduct is larger than the above range, there is concern that the bath becomes instabilized. When the ratio of the amine compound is larger than the above range, an economical disadvantage may result. [0047] The pH of the electroless gold plating bath of the invention is preferably in the range from 5 to 10. When the pH is less than the above range, there is concern that the deposition rate lowers. Over the range, the bath may become instabilized. The pH adjuster used includes sodium hydroxide, potassium hydroxide, ammonia, sulfuric acid, phosphoric acid, boric acid and the like, as employed in known plating baths. [0048] The temperature of the electroless gold plating bath of the invention is preferably in the range of 40 to 90° C. Lower temperatures may lower the deposition rate. Over the range, there is concern that the bath becomes instabilized. [0049] When the electroless gold plating bath of the invention is brought into contact with a palladium plating film, the surface of the palladium plating film can be subjected to electroless gold plating treatment. In this case, a 0.01 to 2 μm thick of gold plating film can be formed in a contact time, for example, of 5 to 60 minutes. The gold plating film can be formed at a deposition rate, for example, of 0.002 to 0.03 μm/minute. [0050] In the electroless gold plating method of the invention, it is possible that the whole of the electroless gold plating film is formed in a thickness of not smaller than 0.15 μm only by the first electroless gold plating. Alternatively, it is also possible that part of the electroless gold plating film is formed by electroless gold plating using the first electroless gold plating bath as set out hereinbefore and a residue of the electroless gold plating film is formed by a second electroless gold plating using a reduction gold plating bath different from the first electroless gold plating bath. In this case, the reduction gold plating bath used is a hitherto known reduction gold plating bath and the gold plating may be carried out under known conditions. [0051] The electroless gold plating method of the invention is suited not only for the case where an electroless gold plating film is formed in a thickness of not smaller than 0.15 μm, but also for the case where the thickness is smaller than 0.15 μm (but not smaller than 0.01 μm), especially, from 0.01 to 0.10 μm, which is adapted for the case where the surface of the electroless gold plating film is used as a solder bonding face. [0052] The electroless gold plating method of the invention is favorable for gold plating treatment, for example, of wiring circuit mounting portions or terminal portions of printed circuit boards, ceramic substrates, semiconductor substrates, IC packages and the like. EXAMPLES [0053] Hereinafter, the invention is particularly described by way of Examples and Comparative Examples. The invention should not be construed as limited to these examples. Examples 1 to 5, Comparative Examples 1 to 4 [0054] Using electroless nickel plating baths, electroless palladium plating baths and electroless gold plating baths, plated film laminates were formed by subjecting substrates to the respective plating treatments under conditions indicated in Table 2. The laminates were evaluated according to the following methods with respect the wire bonding characteristic and solder bondability. The thicknesses and the results of the evaluation of the wire bonding characteristic and solder bondability of the respective films are shown in Table 1. [0055] Solder Bondability [0056] Twenty-point evaluation per condition was made using Bond Tester Series 4000, made by Dage Inc. A solder breakage rate of a breakage mode is shown in Table 1. The measuring conditions are indicated below. In general, the solder breakage rate is evaluated as “good” at 85% or over and as “poor” at smaller than 85%. [0057] [Measuring Conditions] [0000] Measuring system: ball pull test Substrate: BGA substrate (PAT diameter φ of 0.5 mm, made by C. Uyemura & Co., Ltd.) Solder ball: φ 0.6 mm, Sn—3.0Ag—0.5Cu, made by Senju Metal Industry Co., Ltd. Reflow device: TMR-15-22LH, made by Tamura Corporation Reflow condition: Top 260° C. Reflow environment: air Reflow cycles: one and five cycles Flux: 529D-1 (RMA type), made by Senju Metal Industry Co., Ltd. Test speed: 5000 μm/second Aging after solder mount: 1 hour [0058] Wire Bondability [0059] Wire bonding was carried out by use of semi-automatic wire bonder HB16, made by TPT Co., Ltd., followed by 20-point evaluation per condition by means of Bond Tester Series 4000, made by Dage Inc. The W/B (wire bonding) average strength and a coefficient of variation are shown in Table 1. It will be noted that the measuring conditions are those indicated below. In general, the W/B average strength is evaluated as “good” at 8 g or over and as “bad” at smaller than 8 g, and the CV is evaluated as “good” at 15% or below and as “bad” at larger than 15%. [0060] [Measuring Conditions] [0000] Capillary: B1014-51-18-12 (PECO) Wire: 1 Mil-Gold Stage temperature: 150° C. Supersonic wave (mW): 250 (1st), 250 (2nd) Bonding time (milliseconds): 200 (1st), 50 (2nd) Tensile force (gf): 25 (1st), 50 (2nd) Step (length from the first to second): 0.700 mm Measuring method: wire pull test Substrate: BGA substrate, made by C. Uyemura & Co., Ltd. Test speed: 170 μm/second [0000] TABLE 1 Example Comparative Example 1 2 3 4 5 1 2 3 4 Electroless Nickel sulfate (g/L) 20 20 20 20 20 20 20 20 20 Ni Plating Sodium hypophosphite (g/L) 20 20 20 20 20 20 20 20 20 Malic acid (g/L) 10 10 10 10 10 10 10 10 10 Sodium succinate (g/L) 20 20 20 20 20 20 20 20 20 Lead ion (mg/L) 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Sodium thiosulfate (mg/L) 1.0 1.0 1.0 Sodium dithionate (mg/L) 5.0 5.0 Sodium polythionate (mg/L) 7.0 7.0 Sodium dithionite (mg/L) 9.0 9.0 pH 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 4.6 Electroless Palladium chloride (g/L) 5.5 5.5 5.5 5.5 5.5 5.5 Pd Plating Tetramine palladium chloride (g/L) 1.3 1.3 Ethylenediamine (g/L) 25 25 25 25 25 25 25 25 EDTA (g/L) 10 10 10 10 Glycine (g/L) 2.5 2.5 2.5 2.5 Sodium hypophosphite (g/L) 20 20 20 20 20 20 20 20 Acrylic acid (g/L) 25 25 Maleic acid (g/L) 25 25 Fumaric acid (g/L) 25 25 Citraconic acid (g/L) 25 25 pH 8.0 8.0 8.0 8.0 8.0 8.0 8.0 8.0 Electroless Gold potassium cyanide (g/L) 2 2 2 2 2 Au Plating Potassium phosphate (g/L) 10 10 (1) Ethylenediaminetetraacetic acid (g/L) 15 15 15 10 10 formaldehyde sodium bisulfite (g/L) 2 2 Formaldehyde (g/L) 1 1 1 Amine compound 1 (g/L) 20 20 20 Amine compound 2 (g/L) 10 10 pH 7.0 7.0 7.0 7.1 7.1 Plating time (minutes) 10 25 40 12 12 12 Plating time (minutes) of 10 10 electroless Au plating (2) (TAM-55) Plating time (minutes) of 25 25 30 25 electroless Au plating (3) (TMX-22) Film Electroless Ni (μm) 6 6 6 6 6 6 6 6 6 Thickness Electroless Pd (μm) 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 — Electroless Au (1) (μm) 0.05 0.25 0.4 0.05 0.05 0.05 Electroless Au (2) (μm) 0.04 0.04 Electroless Au (3) (μm) 0.35 0.35 0.4 0.35 Evaluation W/B average strength 11.6 13.2 13.8 9.4 14.1 9.1 13.5 11.2 13.4 Coefficient of Variation: CV value 13.3 4.2 5.4 13.9 4.5 18.2 7.9 11.3 5.5 Solder bondability 100 90 50 100 50 100 40 30 50 TAM-55: electroless immersion flash gold plating bath, made by C. Uyemura & Co., Ltd. TMX-22: electroless reduction gold plating bath, made by C. Uyemura & Co., Ltd. Amine compound-1: in the formula (1), R 1 = C 2 H 5 and R 2 = C 2 H 4 OH Amine compound-2: in the formula (1), R 1 = C 2 H 4 OH and R 2 = C 2 H 4 OH [0000] TABLE 2 Temperature Time (° C.) (minutes) Cleaner ACL-009, made by 50 5 C. Uyemura & Co., Ltd. Soft etching Sodium persulfate 100 g/L 25 1 Sulfuric acid 20 g/L Acid rinse Sulfuric acid 50 g/L 25 1 Activator MNK-4, made by 30 2 C. Uyemura & Co., Ltd. Electroless Bath indicated in Table 1 80 30 nickel plating Electroless Bath indicated in Table 1 50 5 palladium plating Electroless Bath indicated in Table 1 80 Time gold plating indicated in Table 1
Part or whole of an electroless gold plating film of a plated film laminate including an electroless nickel plating film, an electroless palladium plating film and an electroless gold plating film is formed by an electroless gold plating using an electroless gold plating bath including a water-soluble gold compound, a completing agent, formaldehyde and/or a formaldehyde-bisulfite adduct, and an amine compound represented by the following general formula R 1 —NH—C 2 H 4 —NH—R 2 or R 3 —(CH 2 —NH—C 2 H 4 —NH—CH 2 ) n —R 4 . The method of the invention does not need two types of baths, a flash gold plating bath and a thick gold plating bath for thickening. Gold plating films of different thicknesses suited for solder bonding or wire bonding can be formed using only one type of gold plating bath. Especially, an electroless gold plating film having a thickness of not smaller than 0.15 μm can be efficiently, effectively formed by use of one plating bath in one step, thereby enabling the process to be simplified along with an attendant advantage in cost.
7
TECHNICAL FIELD In the article of G. L. Moore, et al. entitled Improved Red Blood Cell Storage Using Optional Additive Systems (OAS) Containing Adenine, Glucose, and Ascorbate-2-Phosphate; Transfusion Vol. 21, No. 6, pp. 723-731 (1981), the use of sodium-L-ascorbate-2-phosphate as a component for blood cell storage solutions is disclosed. See particularly page 730. Such a material may be utilized by red blood cells during storage under conventional conditions to provide improved 2,3-DPG maintenance during and after the storage period which improves the cells' oxygen transport. However, sodium L-ascorbate-2-phosphate is not very stable in the presence of autoclave sterilization temperatures (about 110°-122° C.), which of course is necessary procedure for preparing a container with a red cell storage solution therein, so that red cells can be safely stored without sepsis. Specifically, sodium L-ascorbate-2-phosphate tends to degrade during a conventional autoclave sterilization cycle, unless the pH of the solution in which it resides is over 6. However, at such pHs which are over 6, sugars in the solution such as glucose tend to be unstable during an autoclave cycle, forming a colored material (caramelization). Thus, it is very difficult indeed to make use of sodium L-ascorbate-2-phosphate in an otherwise typical red blood cell storage solution, since those solutions generally contain sugar as an energy source for the red blood cells. Since it is generally mandatory to provide autoclave sterilization of containers which carry an amount of red cell storage solution prior to placing red cells in the container, systems which attempt to make use of sodium L-ascorbate-2-phosphate necessarily exhibit serious drawbacks. The compound magnesium L-ascorbate-2-phosphate is a known material, being commercially available. While the compound is soluble in water, current evidence indicates that the ascorbate-phosphate and the magnesium ions do not disassociate in solution. Thus, without wishing to be limited by theory, it appears that the typical molecule in solution may be a dimer, having three magnesium atoms, and a theoretical structure of magnesium-L-ascorbate-2-phosphate in solution of: ##STR1## While the material shown may be hydrated, the compound may also be anhydrous, or provided with greater or lesser amounts of bonded or absorbed water. DESCRIPTION OF THE INVENTION In accordance with this invention, a solution for storing blood is provided in which the solution may be a typically conventional blood cell storage solution either provided in the original collection unit, or as an additive solution for later addition to red cells. The solution contains generally from 3 to 60 millimoles of magnesium L-ascorbate-2-phosphate per liter of solution, or an equal amount of the calcium analog thereof. Significant advantages are achieved by the use of this material in blood cell storage solutions. Magnesium L-ascorbate-2-phosphate is more stable to steam sterilization conditions than the corresponding sodium salt, or free ascorbic acid. Nevertheless, it yields substantially equivalent 2,3-DPG maintenance in red blood cell storage to ascorbic acid and its sodium L-ascorbate-2-phosphate analog. Furthermore, magnesium L-ascorbate-2-phosphate (hereafter "magnesium salt") is stable at pH of less than 7 (e.g. 4 to 7), so that the concentration of the magnesium salt in red cell storage solution may be diminished by no more than about 5 percent during a typical autoclaving, and also improved shelf life is obtained. This, in turn, permits the stabilization of glucose or equivalent sugars, since the solution may have a pH of less than 7 and preferably about pH 5 to 6. For calculation of millimoles, the molecular weight of the magnesium salt is assumed to be 289. The calcium equivalent varies proportionately in its molecular weight. Accordingly, after autoclaving, a sterile red cell storage solution may be provided which contains the magnesium salt with little degradation, and also which contains essentially undegraded sugar, without the undesired, colored materials which are typically formed by exposing glucose or the like to autoclaving conditions at a pH higher than 6 or 7. The corresponding calcium L-ascorbate-2-phosphate may be used as a partial or complete substitute for the magnesium salt described above, to achieve similar advantages. The magnesium salt, or its calcium salt equivalent (calcium L-ascorbate-2-phosphate) may be used in known red cell storage solutions such as ACD, CPD, or adenine solutions. Adenine solution is a product sold by Travenol Laboratories Inc. of Deerfield, Ill., under the registered trademark "ADSOL", being defined herein as an aqueous cell storage solution which contains, per 100 ml. of solution, essentially from 5 to 50 mg. of adenine, from 1,000 to 3,500 mg. of dextrose or fructose, from 400 to 1,200 mg. of sodium chloride, and from 250 to 2,000 mg. of mannitol, as described in U.S. Pat. No. 4,267,269. Preferably, the magnesium or calcium salt is present in a concentration of 5 to 20 millimoles per liter of Adenine solution, or alternatively another red cell storage or collection solution. From 50 to 250 ml. of red cell storage solution may be provided in a conventional blood bag for receiving one blood unit. After autoclaving the bag, the blood may be delivered into the bag and mixed with the red cell storage solution. Alternatively, previously collected packed red cells may be suspended for storage in the solution of this invention; i.e. by either adding the solution to the red cells, or by adding the red cells to the solution. One unit of packed red cells may be suspended in typically 75 to 150 ml. of solution. One unit of whole blood is of typically 513±50 ml. volume, while one unit of packed red cells at an 85% hematocrit is typically 223±30 ml. volume. Long term storage of the red cells, either in the original plasma or preferably as suspended packed red cells, at 4° C. under conventional storage conditions, may then take place for a substantial length of time, for example 35 days, with the red cells exhibiting improved function in accordance with this invention. It may also be desirable for the solution of this invention to contain other materials, for example inosine, guanosine, adenosine or another appropriate purine to provide to the solution an improved capacity for restoration or rejuvenation of 2,3-DPG and ATP in red blood cells after storage. Further in accordance with this invention, one or more L-ascorbate-2-phosphate salts of sodium, potassium, magnesium or calcium may be added to the known Adenine solution of a formula as described above. Not only does such a mixture provide improved 2,3-DPG maintenance for red blood cells during their storage period, but, unexpectedly, reduce hemolysis of the blood cells has been noted, when compared with corresponding blood cells stored exclusively in Adenine solution. For the reasons mentioned above, it is preferred to use the magnesium salt, or alternatively, the calcium salt of the L-ascorbate-2-phosphate. As an added advantage of solutions of this invention, magnesium or calcium is provided to the stored cells, magnesium being of a valuable cofactor, and calcium being also used in cell growth and metabolism. The above disclosure and the example below are offered for illustrative purposes, and are not intended to limit the scope of the invention of this application, which is defined in the claims below. EXAMPLE 1 Solution containing the following, per 100 ml. of solution, was prepared: ______________________________________2000 mg. dextrose anhydrous900 mg. sodium chloride750 mg. mannitol27 mg. adenine220 mg. magnesium L-ascorbate-2- phosphatebalance waterpH 5.2 to 6.8______________________________________ One hundred ml. of the above solution were placed into a Fenwal blood bag and sealed therein. The bag was then sterilized at 238° F. for 45 minutes at a pressure of 29 p.s.i.g. The bag was then pasteurized, after label application, at 182° F. for 60 minutes at a pressure of 8.5 p.s.i.g., and then at 170° F. for 3 hours at a pressure of 8.5 p.s.i.g. No discoloration due to dextrose degradation was noted. Also, the solution was analyzed, and it was determined that the typical loss of magnesium L-ascorbate-2-phosphate was about two percent. EXAMPLE 2 The experiment of Example 1 was repeated, except that the amount of magnesium L-ascorbate-2-phosphate per 100 ml. of solution was 438 mg. After sterilization and pasteurization, the loss of magnesium salt was essentially four percent. No discoloration was noted.
A solution for blood cell storage having sugar-containing blood cell nutrients therein and additionally containing a magnesium or calcium L-ascorbate-2-phosphate salt is taught. The magnesium and calcium L-ascorbate-2-phosphate salts remain stable below pH 7 and thus permit sterilization of the solution at a pH at which degradation of both the L-ascorbate-2-phosphate salt and the nutrient sugar present in the solution is substantially avoided.
8
BACKGROUND OF THE INVENTION In installing underground services, or repairing services already in place, it is quite common to dig a narrow deep trench along the line of the service to the depth at which the service is to be run or to expose the existing service for repair and maintenance. The soil removed from the trench is typically placed on the ground surface immediately adjacent the trench in the area commonly known as the right of way. After the service has been installed or repaired, the trench is refilled with the soil. However, the compaction of the soil is typically less than the undisturbed ground and the soil will commonly overfill the trench, leaving a mound. In the past, various methods and mechanisms have been used to attempt to compact the soil. Specifically, wheels, drums, plates, both static and vibratory, have been employed. All of these have been used in a multitude of configurations, such as rider, walk behind, hand held and the like, and with varying degrees of success. None of the prior devices address the unique problem of returning all of the spoil to a narrow trench. The soil is also quite prone to subsidence as time passes, often necessitating additional efforts to maintain the proper grade level. Because of these facts, the task of trenching to permit the installation or repair of utility services and the restoration of the site back to its preexisting condition, specifically soil density and surface condition, is time consuming and costly. Many times, the trenching crew must return to the site to repair subsidence of the surface and other problems that render the site either unsafe or unsightly. The correction of these problems is usually at the contractor's expense. A need therefore has arisen to develop an apparatus and method whereby the backfilling and compaction of the soil can be done more efficiently and cost effectively. Of specific interest is the ability to compact the soil sufficiently at the time the trench is filled so that subsidence does not occur. Thus, the trencher crew can avoid the costs and difficulty of having to return to a site later. SUMMARY OF THE INVENTION In accordance with one aspect of the present invention, an apparatus is provided for backfilling a trench and compacting soil sufficiently to restore the site. The apparatus includes a tractor and at least one auger mounted on the tractor to move soil from the right of way into the trench. A tamper assembly is mounted on the tractor to tamp the soil into the trench to a compaction comparable with the undisturbed soil to restore the site. In accordance with other aspects of the present invention, the tractor can be hydraulically powered with four-wheel drive. Right and left augers can be employed which are supported at one end by a roller on the ground. The tamper assembly can include a tamping wheel and a vibrating assembly mounted on a mast. The vibrating and tamping wheel assembly is mounted for movement along the mast to move between a position for tamping and compacting the soil and a position for transport of the apparatus. The vibrating and tamping wheel assembly is free-floating on the mast so that the energy of the vibration will be delivered directly to the soil to enhance the compaction. Preferably, the mast can be tilted from vertical to provide the best angle for operation of the vibrating and tamping wheel assembly. The mast is preferably mounted between the front wheels and ahead of the operator's position to provide good visibility. In accordance with another aspect of the present invention, a mechanism is provided for tamping soil into a trench. The mechanism includes a frame, a mast mounted on the frame and a tamping wheel assembly mounted to the mast for movement along the length of the mast. A vibrator is preferably mounted on the tamping wheel assembly. The mast is also mounted on the frame to permit the mast to be tilted from vertical to direct the tamping forces against the soil being compacted in the trench. The self-contained machine of the present invention will backfill and tamp a trench in several passes (trips up and down the trench). It is a dedicated self-propelled rider machine capable of saving the trenching contractor time and money in the restoration of narrow trench excavations. As can be realized, various components and assemblies can be removed from the dedicated self-propelled rider machine and be made available as attachments to other prime movers for the purposes indicated. Thus, these components may be reconfigured to perform the same functions on a variety of other machines, including but not limited to, a small self-propelled walk behind machine. The added benefit of not having to return to the job site at a future date to fill in subsidence can be realized with this machine. BRIEF DESCRIPTION OF THE DRAWINGS For a more complete understanding of the present invention and for further advantages thereof, reference is now made to the following description of the preferred embodiment, taken in conjunction with the accompanying drawings in which: FIG. 1 is a side view of an apparatus forming a first embodiment of the present invention; FIG. 2 is a front view of the apparatus; FIG. 3 is a cross-sectional view of the vibrator and tamping wheel assembly forming a portion of the apparatus; FIG. 4 is a detailed view of the rollers and mast of FIG. 3; FIG. 5 is a front view of the apparatus illustrating the float of the auger when encountering an uneven surface; and FIG. 6 is an illustrative view of an apparatus forming a second embodiment of the present invention which is a small, self-propelled walk behind machine. DETAILED DESCRIPTION With reference now to the drawings, a backfiller tamper machine 10 forming a first embodiment of the present invention is illustrated. The unit includes four major subassemblies, including a tractor 12, a vibrator and tamping wheel assembly 14 mounted on the tractor, a backfill auger assembly 16 and an operator interface 18 for controlling the operation of the tractor and assemblies 14 and 16. The tractor includes a frame 20 supported on the ground by four wheels, including two front wheels 22 and two rear wheel 22. The front pair of wheels are steerable by the operator to guide the unit 10 in the desired direction. For greater control under some circumstances, such as tamping while driving in reverse, rear or all wheel steer may be a desired option. A power unit 24, typically a diesel engine, is mounted on the frame to provide motive power to the unit as well as to power the vibrator and tamping wheel assembly 14 and the backfill auger assembly 16. Preferably, the power unit 24 will drive a plurality of hydraulic pumps for powering the various functions of the unit. Each wheel 22 is preferably driven by an individual hydraulic motor to provide traction. For backfilling and compacting trenches having a width of from four to twelve inches wide and up to 48 inches deep, with 42 inches of cover over the top of the service, the unit would preferably be driven by a 40 horsepower diesel engine. The total weight of this unit would be expected to be about 3800 pounds. However, it will be understood that the unit can be made in any size suitable for the particular trench width and depth to be refilled and compacted. As best seen in FIG. 2, the unit 10 is preferably driven along the trench 26 to be backfilled with the machine straddling the trench. The backfill auger assembly 16 will rotate in the direction of the arrow shown in FIG. 1 and drive the soil 28 from the right of way 30 into the trench. The backfill auger assembly 16 includes a left auger 32 and a right auger 34. Each auger is supported in the vertical direction by a lift cylinder 36 which allows the auger to be moved between a position engaging the ground and a position lifted above the ground for transport and an infinite number of positions between to permit the controlled metering of soil from the pile in the right-of-way into the trench and ahead of the tamping wheel in preparation for tamping. The soil must be returned to the trench in a plurality of passes in order to achieve the proper density. Although varying with soil type and moisture content, typically, proper density can only be achieved in lift thicknesses (depths) of 4 to 8 inches. Also, each auger is mounted through a mechanical pivot 38 which allows the auger to float and thereby follow uneven terrain. As seen in FIG. 5, each auger can pivot independently about pivot 38 to accommodate an uneven spoil pile or uneven terrain. There is a stop 39 to restrict the downward movement of the outer end of the augers about pivot 38 to permit raising the augers to sufficient height for transport and loading of the machine on a trailer. Each auger rotates, raises and lowers and pivots independently of the other, allowing the operator to select either or both augers depending on the task to be performed. To permit ease of operation, each auger is controlled by one hydraulically operated lift cylinder. The pivot 38 is a free floating pivot. As is understood, in order to place all of the soil back in the trench during restoration of the job site, it is necessary to return the soil in a plurality of lifts (layers) of a depth sufficient to allow sufficient tamping force from the tamping wheel to pack the soil. To insure that the proper amount of soil is returned in each lift, multiple trips (passes) must be made and proper metering of the soil into the trench realized by the independent raising and lowering (control) of each auger (right and left) assembly. At the outside end of each of the augers 32 and 34 is mounted a free wheeling roller 40 which supports the outer end of the augers on the ground and prevents them from digging into the surface of the unexcavated ground. The rollers 40 are installed in a removable manner in a hex socket at the end of the augers and are held in place with a bale style pin 42. There are conditions whereby the free wheeling rollers may not be needed. The rollers may be removed and the augers will still perform their function. The pin 42 can be removed and the roller 40 removed as well for installation of an extension auger 44 to either or both the augers 32 and 34, as seen in FIG. 2. The extension auger is secured to the outer end of auger 32 or 34 by the bale pin 42 and the free wheeling roller 40 is, in turn, secured to the outer end of the extension auger 44 by a bale pin 42 to support the augers on the ground. The extension augers are used to manage the larger volume of soil produced by a single side discharge trenching machine or larger spoil piles of deeper and wider trenchers. The extension augers 44 can be stored atop the auger frames 46 when not in use. Each of the augers 32 and 34 is rotated through a dedicated direct drive hydraulic motor 48 mounted on the auger frame 46. Each auger is rotated in a direction to move the soil forward and toward the middle of the machine to deposit the soil into the trench 26 ahead of the vibrator and tamping wheel assembly 14 as the machine moves forward. By rotating the augers in the direction 16a shown in FIG. 1, the augers lift packed soil, fluff it and break up clods. In a typical installation, the augers can be a left hand and a right hand helix, double flight with a 24" diameter and a length of 36". The extension augers can be 18" long. It can also be realized that other methods of moving the soil from the right of way may be employed such as rotating brooms made of bristles of wire or plastic, or mold board (blade) in a "V" configuration. The vibrator and tamping wheel assembly 14 is mounted in a free floating manner on a vertical mast 50. Mast 50 is mounted to the frame in front of the operator interface 18 but behind the front wheel 22. The mast is also pivotally mounted to the frame through pivot pin 52, which allows the mast to be tilted rearward from vertical by a hydraulic cylinder (not shown) to enhance the compaction effect of the vibrator and tamping wheel assembly 14 on the soil as will be discussed in greater detail hereinafter. The vibrator and tamping wheel assembly 14 includes a carriage 54 which mounts a vibrator 56, a tamping wheel 58, rollers 60, lift mechanism 62 and connecting pins 64. The carriage 54 is mounted for vertical motion along the length of the mast 50 through the rollers 60 as best seen in FIGS. 3 and 4. Rollers 60 engage mast roller guide bars 61 on each side of the mast. Preferably, eight rollers are used with the rollers 60 having a V-shape or U-shape cross section to engage the guide bars on the mast 50. The rollers are preferably covered by a soft abrasion resistant material 66, such as urethane, to improve wear life and reduce the noise level during operation. An adjustment mechanism 78 may be employed to adjust the position of the rollers 60 relative to the mast roller guide bars 61. This permits the desired free floating action of the vibrator and tamping wheel assembly 14 to be maintained as the wheels wear during use. The vibrator 56 is preferably a standard rotating eccentric weight vibrator as used on conventional utility cable plows. The vibrator is powered hydraulically from the power unit on the tractor. The tamping wheel 58 is pinned to the vibrator tamping wheel assembly 14 by pin 59, permitting the tamping wheel 58 to rotate about axis 68 to enhance the compacting action. In a typical application, the tamping wheel is a 4" wide by 30" outside diameter sheep's foot style tamping wheel. The tamping wheel can also be a smooth roller or other configuration. This wheel and wheel yoke is pinned to the carriage 54 by two 11/4" connecting pins 64 installed in hardened steel bushings. This pinning method allows for easy conversion to a larger diameter and/or a wider or different style tamping wheel. As can be understood, the weight of the vibrator and tamping wheel assembly 14 will cause it to slide down the mast and into contact with the soil placed in the trench by the backfill auger assembly. The vibration of the vibrator 56 and operation of the tamping wheel 58 will cause the soil to be compacted to a degree sufficient to restore the trench after several passes. With the vibrator and tamping wheel assembly 14 free floating on the mast, a minimum amount of vibration is induced into the tractor, and the unit 10 is therefore more comfortable for the operator and provides reduced wear and damage to the tractor. Because less vibration is induced into the tractor, the amount of work (vibration) applied to the soil to be compacted is increased, resulting in a more efficient compaction effort than current art. It will be readily understood that other methods of permitting the vibrator and tamping wheel assembly 14 to float on the mast are possible. However, unless the assembly is isolated from the mast and lift mechanism, vibration will be transmitted to the tractor and the operator, resulting in discomfort for the operator, damage to the equipment and reduced compaction efficiency. After the compaction effort is complete, the lift mechanism 62 can be operated to lift the carriage 54 and tamping wheel 58 above the ground surface. The lift mechanism 62 includes a hydraulically operated winch 70 mounted at the top of the mast and a winch cable 72 attached to the carriage 54 for lifting the vibrator and tamping wheel assembly above the ground level. When the higher position is reached, a positive mechanical spring loaded retainer mechanism 74 will engage the carriage 54 and hold the vibrator and tamping wheel assembly 14 in the raised position mechanically. Mechanical retention of the mechanism is desired as the hydraulic motor of the winch will leak down after the power unit is shut off, allowing the vibrator and tamping wheel assembly 14 to move by gravity from the desired transport position. The vibrator and tamping wheel assembly lock mechanism 74 is engaged and disengaged through a push pull control cable 95 at the operator interface 18. During operation, the vibrator and tamping wheel assembly 14 is lowered to a position engaging the soil to be compacted. The hydraulic valve in the winch 70 is positioned in a float orientation, allowing the cable drum to spool out cable 72 as the elevation of the soil in the trench and the surrounding surface conditions vary. Thus, the vibrator and tamping wheel assembly 14 is free floating along the length of the mast, which enhances the isolation of the assembly 14 from the rest of the tractor and results in greater compaction efficiency. The vibrator 56 is controlled through a hydraulic valve that permits the operator at the operator interface 18 to select an infinite range of vibration frequency and amplitude. Thus, the operator can adjust the machine performance to optimize performance to the soil type and conditions experienced. The mast 50 is preferable tilted toward the rear of the tractor as seen in FIG. 1 at about ten degrees. The mast tilt angle, however, can be changed by pivoting the mast about pin 52 to improve the vector 76 of force F and force angle α applied to the soil in a variety of soil types, tractor speeds and conditions. By directing the compaction force vector 76 in the optimum direction, the compaction is more efficiently and effectively conducted. In addition, the angle adjustment feature reduces the potential for the carriage mechanism to become bound to the mast. This is because the angle can be adjusted so that the force of the tamping is directed parallel the direction of movement of the vibrator and tamping wheel assembly 14 along the mast so that no force is actually exerted by assembly 14 into the mast. The angle change permits the carriage and roller assembly to roll up and down the mast more easily as soil conditions and types vary. While unit 10 has been described as an integrated apparatus with transport, fill and compactor capabilities, it will be understood that various elements of the unit, such as the vibrator and tamping wheel assembly and the backfill auger assembly can be configured and adopted as an attachment to a standard trencher. In addition, a trencher can be attached to unit 10 to provide a complete installation and restoration machine. The operator's area 82 is preferably located on the left side of the power unit 24. While in the operator's seat 84, the operator will be able to easily see the vibrator 56, the tamping wheel 58, the augers 32 and 34 and the trench 26. Tractor forward speed and direction control is achieved by depressing a foot pedal 86 located on the floor board at the operator's right. It can be readily understood that other methods of speed and direction control such as a hand operated vernier control handle is possible. Steering is controlled through a conventional steering wheel 88. Control of auger rotation, auger lift, vibrator operation and raising and lowering of the assembly 14 by the lift mechanism 62 is achieved by movement of various hydraulic control valve handles 90. All machine functions are controlled from the operator's position. The operator will be protected from a machine rollover by a rollover protective structure (rops) 92 and seat belt 94. Operator visibility is a primary concern. In order for the operator to work efficiently and safely, the trench 26, right of way 30, augers 32 and 34 and tamper wheel 58 must be easily seen from the operator's area. The configuration of the unit 20 provides the operator with excellent visibility. With reference now to FIG. 6, a second embodiment of the present invention is illustrated as backfiller tamper machine 100. In all essential aspects, the machine 100 is identical to the machine 10. However, the machine 100 is adapted to be controlled by an operator walking behind the machine such as would be the case with a handlebar trencher or lawn mower. As can be understood other methods of operation may also be used such as an umbilical cord and remote radio control. The machine 100 has a control panel 102 with suitable controls as used on machine 10 to permit the operator to control the machine 100. The controls can either be mounted on handles extending rearward from the machine or at the rear of the machine, or a combination thereof, within ready access of the operator. Normally, a machine such as machine 100 would be downsized from the machine 10 with its components downsized correspondingly. Although the present invention has been described with respect to a specific preferred embodiment thereof, various changes and modifications may be suggested to one skilled in the art, and it is intended that the present invention encompass such changes and modifications as fall within the scope of the appended claims.
A backfiller and tamper unit (10) is disclosed which is a self contained unit that acts to both backfill and compact soil into a trench for complete restoration. The unit includes a tractor (12) which mounts a vibrator and tamping wheel assembly (14) and a backfill auger assembly (16). The vibrator and tamping wheel assembly (14) is mounted on a mast (50) which is pivotally secured to the tractor for limited arcuate motion from vertical. This permits the mast to be tilted so that the compaction force of the vibrator and tamping wheel assembly is most effectively directed to compact the soil in the trench. The vibrator and tamping wheel assembly is free floating on the mast which isolates the tractor from vibration generated by the vibrator and tamping wheel assembly and provides greater compaction efficiency. Further, the vibrator and tamping wheel assembly can be lifted vertically on the mast by a lift mechanism (62) for storage.
4
FIELD OF THE INVENTION [0001] The present invention is related to a signal cable and its application. BACKGROUND OF THE INVENTION [0002] A signal cable is a cable for transferring high level input from an audio amplifier to a speaker or a loudspeaker. It is composed mainly of two wires insulated with plastic. It is most commonly described by the surface area of the conductor, as expressed in square millimeters, e.g. 2×1.5 mm 2 , 2×2.5 mm 2 , etc. The marking also uses the designation AWG unit. A cable with a larger diameter makes less resistance to the signal. [0003] The invention relates to graphene connecting wires, especially for audio systems, for example, used to connect a turntable with preamplifier called interconnects in the audio industry and cables that connect a specific LF amplifier with a speaker system. These are crucial elements of a passive audio track. [0004] Wires connecting the turntable preamplifier and cables connecting the amplifier with the speakers are a very important part of a sound track often giving an ungroomed character to the sound of music programs, music, and affect the unreadability of musical instrument sounds and speech. The use of poor quality cables clearly breaks or degrades readability, colour, understanding and sound quality. Cables and wires form a kind of transmission medium for acoustic waves of the whole spectrum of the sound spectrum bands connecting the amplifier with speakers. They are supposed to transfer both the signal of small amplitude and large amplitude to and from an audio amplifier to a speaker or a loudspeaker. Therefore, their quality is extremely important if for fidelity and quality of sound reproduction fed from the source to the amplifier, or for understanding, reading the information contained in the audio signal. [0005] Speaker cables and interconnects are made up mostly of two electrical conductors insulated with plastic. An important parameter of interconnects and speaker cables is a cross-section of electrical cable, frequently described by the conductor surface area constructed of copper, expressed in square millimeters, for example 2×0.5 mm 2 , 2×1 mm 2 (interconnects), 2×1.5 mm 2 , 2×2.5 mm 2 (power cables), etc. A cable with a larger diameter makes less resistance to the signal which is favourable for direct impact on the power fed back into the speakers. Less power is dissipated in the transmission medium with a larger cross-section so more energy (power) arrives at the speakers. This is important information directly relating to users of audiophile tube power amplifiers in SE (Single End) configuration, whose output power is approx. 8, for amplifiers built on tubes, for example 300B, 2A3 and similar or transistor amplifiers working in the class A. with an output power not usually exceeding approx. 15 W. [0006] Similar expectations apply to the cables connecting the turntable and the preamplifier. But in this case we do not use and do not have high power of the transmitted signal that are more resistant to external interference. On the contrary, in the interconnects we are dealing with small signals, where very high resistance is important and their susceptibility to interference reaching and besieging them from the outside negligible. When strengthening this type of signals minimal own medium, i.e. interconnects, noise is necessary and indeed indispensable. Unwanted own characteristics, though characteristic of each medium, will always be present, i.e. capacitance, inductance, resistivity, which have a direct impact on the spectrum and audio quality, or the quality of information, which is reinforced in subsequent stages audio system can affect the information. [0007] The publication CN 103123830 A discloses a layered material, wherein the graphene is “located” between the insulating and conductive material in the form of two-dimensional monatomic or polyatomic structured layer. The insulating material proposed is, polyethylene, polyvinyl chloride, etc. And the conductive material proposed is copper, aluminum, silver or gold. [0008] According to the publication CN 103123830 A the layered material is to be wound into a roll in order to obtain the desired effect, then one, two or more such rolls placed in a rubber tube to obtain cable for high voltages. The disadvantage of this is the use of precious metals as a conductive material, which increases the cost of the production of cables, as well as the necessity of rolling the roll, which is not convenient for the production of such cables and causes additional costs. The power cable known from CN 103123830 A is also not suitable as a signal cable for connecting audio, video or measurement devices. [0009] Also the publication CN 203617033 U represents the utility model of cable for high voltages, which comprises several rollers in the middle, wherein each roll has a material containing a microchip with graphene uniformly dispersed in polyethylene. The diameter of the graphene microchips is not greater than 10 microns. [0010] The publication CN 103811095 A discloses graphene cable comprising a metal core and a layer of graphene. The layer of graphene comprises from 1 to 10 layers of graphene deposited from vapour on a metal core. The metal core is made of copper, iron, aluminium or other metals, it may also be covered with another metal from the group: scandium, titanium, silver, chromium, manganese, iron, cobalt, nickel, copper, zinc, technetium, ruthenium, silver, cadmium, lutetium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, molybdenum, gold, etc. OBJECTS AND SUMMARY OF THE INVENTION [0011] According to the invention the signal cable for transmitting the signal between the transmitter and the receiver, providing an electrical connection by a connecting part, wherein said connecting portion comprises a layer of graphene disposed on a polymer layer, characterised in that it comprises two conductors, wherein each conductor includes a connecting portion arranged in a protective insulating layer and the coupling portion takes the form of a tape, in which the graphene layer is disposed between two polymer layers. [0012] Preferably, the two wires are connected together along one edge of the protective insulating layer. [0013] Preferably graphene layer is in a two-dimensional form having a thickness of one atom or more than one atom or three dimensional and preferably they are nanotubes arranged in different directions, in particular parallel or perpendicular to the surface of the polymer. [0014] Preferably, the polymer layer is a polymer selected from the group consisting of polyethylene terephthalate (PET), polyethylene naphthalate (TEN), polyethersulfone (PES), and polycarbonate (PC), polypropylene (PP), poly(ethylene oxide) (PEO), poly(vinyl chloride) (PVC), synthetic rubber, most preferably: polyethersulfone (PES), polycarbonate (PC). [0015] Preferably, the protective layer is a layer with a very high resistance, preferably made of a material selected from the group including: Teflon, polyethylene terephthalate (PET), polypropylene (PP), poly(vinyl chloride) (PVC), synthetic rubber. [0016] Preferably, the graphene is in its pure or doped form. [0017] Preferably, each of the connectors includes plugs: the first plug for connecting a signal transmitter, and a second plug intended for connection to a signal receiver electrically connected by a connecting part. [0018] The invention further encompasses the use of the signal cable to transmit the signal between the transmitter and the receiver. BRIEF DESCRIPTION OF THE DRAWINGS [0019] The invention will now be further described in the preferred embodiment, with reference to the accompanying drawings, in which: [0020] FIG. 1 shows a cross section of the interconnect (speaker wire) of the invention embodiment. [0021] FIG. 2 shows the physical form of the medium on the basis of graphene to be used for interconnects. [0022] FIG. 3 shows the physical form of the medium on the basis of graphene to be used for speaker cables. [0023] FIG. 4 shows the connection of sound sources with preamplifier and power amplifier, [0024] FIG. 5 shows the combination of an amplifier with loudspeaker system. DESCRIPTION OF EMBODIMENTS [0025] Specific embodiments of the invention will now be described with reference to the accompanying drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements. [0026] The figures use the following indications: 1 —graphene; 2 —polymer; 3 —the protective layer, for example, Teflon; 4 —preamplifier and amplifier; 5 —signal source, e.g. DVD/CD player; 6 —speakers. [0027] The disclosed wires, both interconnects and speaker wires, contain a graphene layer 1 disposed between two polymer layers 2 , which is not the signal carrier. The transmission medium is graphene. [0028] Said polymer layer 2 is a polymer selected from the group consisting of polyethylene terephthalate (PET), polyethylene naphthalate (TEN), polyethersulfone (PES), and polycarbonate (PC), polypropylene (PP), poly(ethylene oxide) (PEO), poly(vinyl chloride) (PVC), synthetic rubber, most preferably: polyethersulfone (PES), polycarbonate (PC), which ensure its integrity, hardness, flexibility, resistance to compression. [0029] Graphene layer 1 , provides very good conductive properties while maintaining the transparency of the material. Interconnects (wires) are enclosed in a protective Teflon insulation layer 3 with a very high resistance, which is so inert that it does not affect the nature of the transmitted information. Graphene layer 1 is homogeneous and forms a surface characterised by a uniform level of electro-acoustic-wave propagation, which is audio signal composed in many ways. Accordingly, due to the fact that graphene has a two-dimensional structure (homogeneous) electrons move in one, or in a controlled plane (as free electrons) to either the front or the back (in copper as free electrons they move chaotically and in multi-dimensional structure). The cross-section of a medium for the transmission of sonic signals built on the basis of graphene is shown in FIG. 1 . [0030] Cables built with graphene provide a high level of electroacoustic properties, which is a transmission medium of almost perfect characteristics. Reference signal, in this case, from the source 5 which is a turntable, a preamplifier, a power amplifier, seen as the output signal is matched in phase of the signal, the minimum power loss, a short propagation time, a short unit of time for transmission of energy of low-frequency to a load which are speakers, low noise floor, it is almost identical to the reference signal source. It is characterised by considerable indifference to inducing a spurious HF electromagnetic energy (High Frequency Energy) that passes through the presented cable in its various sections, and also has a resistance to RFI (Radio Frequency Interference) and EMI (Electro Magnetic Interference), which comes with a minimum capacity and inductance of the electrical structure of graphene. In addition, the presented passive elements of the audio track meet the requirements for mechanical strength. The physical form of a medium for the transmission of sonic signals built on the basis of graphene is shown in FIG. 2 and FIG. 3 . FIG. 2 shows the physical form of the medium on the basis of graphene to be used for interconnects, and FIG. 3 shows the physical form of the medium on the basis of graphene to be used for speaker cables. [0031] Commonly used speaker cables have sufficiently large cross-sections depending on the power of an audio amplifier, so as not to cause loss of power. The thinner the cross-section, the higher the resistivity, so more power loss hangs on the cable and less on the speaker terminals. Minimum wire cross-section (medium) connecting the amplifier with the speaker system should have a larger cross-section than the calculated one, but it should not be less. It should be mentioned here that an important determinant of minimum quality speaker cables is so called damping coefficient. It is an important parameter for electroacoustics laws given in the amplifier manual as Damping Factor (DF). [0032] For the calculation of the minimum cross-section of a single conductor of a speaker cable, a definite damping coefficient for the entire system, amplifier, cables, speakers is assumed, but no more than given by the manufacturer of the amplifier (DF). Usually it is 200 (at 1 kHz for 80 load at 40 will be higher), although this value often increases at low frequencies and can even reach 1400. Assuming higher values of DF creates higher demands for the system for efficiency and, as one may guess, larger cross-sections of wires are used. These considerations apply to cables commonly used in audio equipment, as well as due to the relatively large parasitic phenomena relating to options other than graphene options. The connection of sound source 5 with preamplifier or amplifier 4 is shown in FIG. 4 . In contrast, connection of amplifier 4 with a loudspeaker system 6 is shown in FIG. 5 . [0033] In the proposed solution there is no need to use thick, heavy cables, if with no loss of sonic qualities better, thinner, lighter, faster cables and interconnects can be used. The use of graphene cable to the speakers or loudspeaker also eliminates other problems with the speaker cables, which in the case of using a cable built based on graphene technology compared to technology based on, for example, copper almost does not exist, i.e. oscillations of the parasitic nature over acoustic. [0034] Such oscillations can be clearly seen on the oscilloscope. Their symptom is usually unjustified heating of the amplifier heat sink, even with minimal input signal, and even in its absence due to the nature of the medium (inductance, capacitance, resistance). The formation of oscillations of a hum impact of SEM (strength of electromagnetic energy at a frequency of 50 Hz and harmonics) of high-field inductions in interconnects and audio cables. Oscillations can cause hyperactivity of the protection circuitry, resulting in malfunction of the amplifier. In the case of the use of these media active audio tracks can be minimized, so low pass filters in the amplifier degrading sound, bindings (twisting) of the conventional speaker cables brought out of the power amplifier or can be dispensed with. What affects the appearance of parasitic capacitance and lowering the frequency response of audio bandwidth thereby worsening the quality of sound reproduction. [0035] It is well known that every element of the acoustic route and the design of preamplifiers and power systems, medium (transmission line) has an impact on the nature of sound quality SVM drive amplifier, and consequently speaker units. The type and quality of the components used to build audio transmission paths connecting the particular microphone preamplifiers, CD and DVD drives with power amplifiers and speaker systems have significant and not contestable influence on the character and quality of sound creation. In a situation where we use the media presented one has the impression that the character of the sound is created only by active elements. The transmission line—the presence of media on the basis of graphene in terms of acoustics is not felt. Transmission, reproduction and creation of sound occur by means of active audio track. [0036] The use of interconnects and speaker cables constructed on the basis of graphene has a positive effect on the operation of individual degrees LF and significantly affects the quality and fidelity of sound reproduction by the system or audio device. [0037] The present invention relates to transmission media, i.e. Interconnects and speaker cables made of graphene, which have the following characteristics: The vast flow velocity of electrons, about 1/300 the speed of light is the flow of electrons in the medium of graphene. They are characterised by substantial indifference to ubiquitous electromagnetic energy interference with low and high field intensity at high frequencies. Almost no formation of oscillations of a hum under the influence of electromagnetic energy at a frequency of 50 Hz and harmonics of high electromagnetic field intensity generated by long power cables, transformers, power supply circuits, etc. Very small capacitance, inductance and resistivity. Therefore, the said parameters minimally affect the sonic qualities of the audio systems working on graphene-based media. Very good mechanical strength and low weight compared to interconnects, cables built in technology based on, for example, copper, etc. Lack of parasitic excitation of audio sets of over-acoustic character present compared to cable interconnects constructed in technology based on copper. Lack of additional electromagnetic screens, which often in addition to improving these properties and performance degrade them and generate unnecessary costs. First and foremost they are characterised by pure, detailed, neutral, fully controlled sound reaching our consciousness, subconscious and superconscious. [0046] The disclosed passive elements of the audio track can be used both in professional and commercial audio-video equipment. The disclosed transmission media are especially recommended to: electroacousticians, sound engineers and producers, musicians, music lovers, audiophiles, etc. [0047] Interconnects can also be part of a larger whole, i.e. the microphone track, alone or being part of a mixer, console, including additional signal processors, such as, for example a noise gate, filters, dynamics compressors, parametric equalisers, limiters, and other types of equipment used in the audio art. [0048] They can also act as media for connections: analogue, audio signals, mono, stereo, video signal, composite, RGB, aerial, digital connections, multi-channel, etc. [0049] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the drawings and descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
The present invention is a signal cable for transmitting the signal between the transmitter and the receiver, providing an electrical connection by a connecting part, wherein said connecting portion comprises a layer of graphene disposed on a polymer layer, characterised in that it comprises two conductors, wherein each conductor includes a connecting portion arranged in a protective insulating layer ( 3 ) and the coupling portion takes the form of a tape, in which the graphene layer ( 1 ) is disposed between two polymer layers ( 2 ).
7
RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 60/992,350, filed Dec. 5, 2007 and is herein incorporated in its entirety by reference. FIELD OF THE INVENTION The invention relates to a winding core and bolt, and more particularly, to an extruded wood fiber core with an applied solid wood exterior shell. BACKGROUND OF THE INVENTION Wood fiber cores have been used in applications utilized for winding or spooling industrial products. Extruded wood fiber cores, such as those manufactured by the assignee since the mid 1960's, have been suitable for applications where low cost is valued, and where durability is not essential. Wood fiber cores have excellent compressive strength in the axial direction, but only moderate or poor tensile strength in the transverse direction. Such fiber cores may be extruded or molded. Wood fiber cores are typically limited to single use as they lack beam strength, and unwinding of materials from the core can produce cracks, fissures or other structural defects rendering them inoperative. Solid wood cores are manufactured using labor intensive machining of lumber, gluing, clamping and various steps. While more expensive than extruded core, the solid wood provides improved structural integrity for heavier materials or multiple use applications. Such solid wood cores are of particular value in intracompany uses. Such solid wood cores have improved beam strength. Similarly, the steel cores are highly durable, but require expensive fabrication and welding, are heavy, and are expensive to ship. What is needed, therefore, are techniques for providing durable, reusable cylinders manufacturable with low labor. SUMMARY OF THE INVENTION One embodiment of the present invention provides a method for the production of winding cores with a solid wood exterior, the method comprising: providing a extruded wood core column; providing a plurality of solid wood staves having an interior profile mating an exterior profile of the extruded wood column; applying an adhesive to the interior profile of the staves and the exterior profile of the core; adhering the interior profile of each of the staves to the exterior profile of the core; mechanically securing the staves to the core; allowing the adhesive to cure providing a winding core with a solid wood exterior. Another embodiment of the present invention provides such a method further comprising placing at least one steel band about an end of the winding core with the solid wood exterior and embedding the band in the solid wood exterior. A further embodiment of the present invention provides such a method further comprising disposing at least one end cap on an end of the winding core with the solid wood exterior and crimping the end cap to secure it to the winding core with the solid wood exterior. Yet another embodiment of the present invention provides such a method wherein step of mechanically securing comprises nailing the staves to the extruded core. A yet further embodiment of the present invention provides such a method wherein the step of mechanically securing comprises clamping the staves to the extruded core. Still another embodiment of the present invention provides such a method further comprising machining the staves from wood of a variety selected from the group of wood varieties consisting of poplar, oak, ash, maple, mahogany, and walnut. A still further embodiment of the present invention provides such a method wherein the wood is an exotic species of wood. Even another embodiment of the present invention provides such a method further comprising fluting the staves. An even further embodiment of the present invention provides such a method further comprising shaping the staves such that the solid wood exterior is tapered. Still yet another embodiment of the present invention provides such a method wherein the solid wood exterior comprises a parabolic frustrum. One embodiment of the present invention provides a structural unit; the structural unit comprising: a extruded core comprising wood fiber and a thermoset resin having a central hole coaxial with a major axis of the core and an exterior; a plurality of shaped staves forming a shell, each stave of the plurality of staves disposed about the exterior of the core and parallel to the major axis. Another embodiment of the present invention provides such a structural unit further comprising at least one slot disposed in at least one the stave is provided parallel to the axis. A further embodiment of the present invention provides such a structural unit wherein the plurality of staves form a cylindrical shell around the core. Yet another embodiment of the present invention provides such a structural unit wherein shell has groves where the staves meet. A yet further embodiment of the present invention provides such a structural unit wherein the staves are manufactured from a wood, the wood being of a wood species selected from the group of species consisting of poplar, pine, oak, mahogany and walnut. Still another embodiment of the present invention provides such a structural unit wherein the staves are tapered, such that the staves form a smooth, longitudinally tapered shell around the core. A still further embodiment of the present invention provides such a structural unit, wherein the shell is fluted. The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective drawing illustrating an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 2A is a top plan view drawing illustrating a smooth stave of an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 2B is an elevation view drawing illustrating a smooth stave of an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 2C is a bottom plan view drawing illustrating smooth stave of an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 3A is a top plan view drawing illustrating a fluted stave of an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 3B is an elevation view drawing illustrating a fluted stave of an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 3C is a bottom plan view drawing illustrating a fluted stave of an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 4 is a cross sectional plan view illustrating an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention and having a spiraled cross section. FIG. 5 is a cross sectional plan view illustrating an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention and having retention slots disposed in the solid wood shell. FIG. 6 is an elevation view illustrating an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention having a retention slot. FIG. 7 is an perspective view illustrating an extruded core cylinder for sheathing with a solid wood shell configured in accordance with one embodiment of the present invention. FIG. 8 is an elevation view illustrating an extruded core cylinder with a solid wood shell configured in accordance with one embodiment of the present invention undergoing clamping. FIG. 9 is a prospective drawing illustrating a structural cylinder having a shell having a non-cylindrical profile configured in accordance with one embodiment of the present invention. DETAILED DESCRIPTION As illustrated in FIG. 1 , a cylinder 12 of extruded wood fiber disposed in a resin matrix 13 is provided by one embodiment of the present invention. The extruded core 12 is covered in a shell 18 of wooden staves 14 . In one embodiment of the present invention, each stave 14 covers one eighth of the circumference of the extruded core 12 . Staves 14 , according to one embodiment of the present invention, are glued to the exterior of the extruded core 12 . Nails 15 may be used to affix the staves 14 to the core 12 while the glue cures, and may add additional strength to the bond between the staves 14 and the core 12 . During manufacture, staves 14 may be clamped to the core 12 to insure proper curing of the adhesive manually, using pipe clamps or other suitable hand clamp with a circular pressure ring, or may be clamped using a automated device whereby pressure is applied to the circumference of the stave shell. In one such embodiment pneumatic pressure may be applied, such as by an air choke. For example, Air Flex® clutch break single and double flange elements, part no. 142197JA sold by Eaton Corporation may be used. A central extruded bore 16 is provided through the core 12 to permit the introduction of shafts or other mounting means as necessary. Staves 14 , are illustrated in greater detail in FIGS. 2A-3C . In one embodiment of the present invention, illustrated in FIG. 6 a slot 22 may be machined in one or more of the staves to allow the introduction of a tongue or anchor into the roll so as to facilitate the anchorage of the material to be wound upon the roller to the roller. Alternative retention means, including a spiraled cross section, and a plurality of retention slots are illustrated in FIGS. 4 and 5 , respectively. In one embodiment of the present invention, and end cap may be placed over each of the ends of a completed composite core thereby providing improved radial strength. Such caps are known to those skilled in the art and are used with known solid wood cores. In alternative embodiments where such strength is unimportant, such an endcap is unnecessary. In one embodiment of the invention, the staves 14 may be configured with an exterior profile such that when each stave 14 is applied to the core 12 such that the elongate length of the stave 14 is parallel to the axis of the core 12 , the exterior profile of the stave is rounded to form an arc, and the arcs of the eight staves combine to form a circular cross section. In alternative embodiments where the core may be used as structural or esthetic architectural element, the staves may be machined prior to application to provide a suitable taper to the column, as illustrated in FIGS. 2A-2C , or in some embodiments fluting as illustrated in FIGS. 3A-3C . Such a taper may be obtained by applying a “shoe” to the stave during machining. In such esthetic embodiments, the staves may be applied to the core without nails, so as to avoid marring the surface of the lumber, alternatively an additional step may be employed wherein nail holes are filled with wood putty prior to sanding and finishing. One skilled in the art can appreciate that suitable capitals or other ornamental end pieces may be applied. The interior profile of each stave 14 , in one embodiment is curved to provide optimum contact with the exterior surface of an extruded core having a circular cross section. As noted above, in one embodiment, staves may comprise eight staves disposed about the circumference of the extruded core, while in alternative embodiments, different numbers of staves may be employed. Similarly, various cross-sectional shapes may be imparted to the extruded cores. In alternative embodiments where extrusions of square, polygonal, pentagonal, hexagonal, heptagonal, octagonal, nonagonal, or decagonal cross section or cross sections of any number of sides, staves with flat interior sides may be provided. In such embodiments same number of staves as of sides may be used. Similarly, in other alternative embodiments, staves may be milled to match the profile of the extruded core. It is noted, however, that polygonal cross sections can reduce the waist rate of the milled staves as the milled stave need only be milled on the exterior. Wood used in the construction of staves may, in one embodiment be wood from trees of the genus Populus . Other inexpensive, easily milled, woods may be used. The density of the wood may likewise be selected based upon factors including the desired durability of the unit produced, the weight and strength requirements, and a need for relative flexibility may be considered. Other suitable woods may include softwoods such as pine or hardwoods such as oak or maple. Exotic species, like mahogany, rosewood, and teak may also be used in applications where the esthetics of the finished piece require such woods. Glues used in the adhesion of the staves to the core are chemically and structurally compatible with the resins used in the core. Degradation of the core could compromise strength of the system. In one embodiment wood glue, such as that available under the trademarks Elmer's and Tightbond, may be used. Alternatively, resins similar to or identical with that used in the wood fiber extrusion may be used. In one such embodiment both the extrusion and the glue are Urea-Formaldehyde resins. The setting of the Urea-Formaldehyde resin may be accelerated using catalysts. Examples of catalysts used include various metal salts, such as aluminum sulfate. In one embodiment of the present invention, first and second bands 20 are disposed about first and second ends of the shell 18 . In one embodiment these bands may be configured from steel or other suitable, high tensile strength material. These bands 20 may be disposed in rabbeted channels disposed in the shell 18 . Alternatively, the tightening of the bands 20 may depress the wood staves sufficiently to keep the steel band 20 from contacting items coiled about the shell 18 . The ends of the bands 20 may be crimped or buckled to ensure a secure and low profile joint. In some embodiments, the crimp or buckle may be recessed in a receiving recess. The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
A method and is disclosed for the production of winding cores having a solid wood exterior. The method comprises adhering a plurality of staves about the exterior of the extruded wood core, such that those staves form a shell.
4
BACKGROUND OF THE INVENTION 1. Field of the invention The present invention relates to an optical fiber probe and cantilever. having a microscopic aperture, used in a scanning near-field microscope, and to a method of forming this aperture. 2. Description of the Prior Art An optical fiber probe of a scanning near-field microscope of the related art is manufactured using the type of method described below (1) Tip sharpening step {circle around (1)} Hot pulling method: heat is applied to the optical fiber probe, etc., and the optical fiber is pulled in an axial direction to sharpen the tip. {circle around (2)} Etching method: the optical probe is immersed in etching fluid, and the tip is sharpened under predetermined etching conditions. (2) Aperture forming step {circle around (1)} Oblique vapor deposition method: an aperture section of the extreme tip section of the sharpened probe are left behind, and a metal is vapor deposited from an oblique direction so that sections other than the aperture are covered with a metallic film. {circle around (2)} Pressing method: After a metallic film has been vapor deposited on a section including a tip section, the tip section is pressed against a sample surface to form an aperture. With this method, the probe is brought into contact with a detector surface made of silicon utilizing shear force, while carrying out distance regulation, and after contact the tip is broken using an external. impulsive force etc. while monitoring the detector output, until a desired output is obtained. Also, in the case where a bent type optical fiber probe is processed, a bending step is carried out between the steps (1) and (2) described above. In the bending step laser light is applied to the sharpened probe, and the optical fiber is softened by the thermal effect. At this time, the probe is bent by a surface tension effect of the softened optical fiber material. The manufacturing steps as described above are disclosed, for example, in the near-field nanophotonics handbook, 23-28 and 42-48, optronics society. Also, the method of forming an aperture by pressing an optical fiber probe is described in a “fiber probe aperture control method for near-field light microscope” by Teruyama and Saiki, 46 th lectures of the applied physics association, 1030. On the other hand, with a scanning near-field microscope, a cantilever with a microscopic aperture is also used (for example, H.Zhou, A.Midha, L.Bruchhaus, G.Mills, L.Donaldson, and J. M. R.Weaver: Novel SNOM/AFM Probes by combined Micromachining and Electron-Beam Nanolithography, Preliminary Proceedings of STM '99, 459). A cantilever with a microscopic aperture has a cantilever section and a probe formed of a silicon nitride or silicon material using a semiconductor process, a microscopic aperture is provided in the probe tip, and the microscopic aperture is made into a through hole so that a beam is focused by an objective lens onto a rear surface of the cantilever, passed through the through holes and a laser beam is introduced. The tip section is also covered with a metallic film in the cantilever having a microscopic aperture. However, with the aperture forming method of the related art, there are the following problems. (1) In the case of the oblique vapor deposition method, in order to make an aperture with good reproducibility, it is necessary to optimize vapor deposition conditions. This optimization requires time, and also, in the case where the probe shape is altered, it is necessary to carry out the optimization again. Further, it is not possible to avoid variations in aperture diameter, even after optimization. Once the aperture have been formed, it is impossible to correct them and defective products must be discarded. (2) In the case of the pressing method, light output is being monitored at the tome of forming the aperture, which means that thee is the advantage that a desired aperture can be obtained. However, with the method of the related art, it is difficult to regulate the pressing force, and fine adjustment of the aperture diameter is difficult. Because of this, it is often the case that the aperture diameter becomes bigger than a desired diameter because the pressing force is to large, or the tip is damaged and the shape of the aperture becomes elliptical. In order to solve these problems in the related art, an object of the present invention is therefore to provide an optical fiber probe and a cantilever having a microscopic aperture, capable of obtaining an aperture of a desired diameter with good reproducibility, and finely adjusting a force for plastic deformation or breaking of a tip, and a method of forming this aperture. SUMMARY OF THE INVENTION In order to solve the foregoing problems in the conventional art, the optical fiber probe and cantilever with a microscopic aperture of the present invention includes means for bringing a probe tip and a sample close together or into contact with each other utilizing an atomic force or shear force acting between the optical fiber probe or the. probe tip of the cantilever with a microscopic aperture, or a tunnel current or evanescent light, regulating a force on the probe tip with a physical amount of any of these as a parameter, and forming an aperture of a desired diameter at the tip section by plastic deformation or breaking of the tip section of the probe using a force received from a sample surface. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of an apparatus for forming an aperture in a tip of a bent type optical fiber probe using a contact mode AFM regulation method, being a first embodiment of the present invention. FIG. 2 is a schematic diagram of an apparatus for forming an aperture in a tip of a cantilever having a microscopic aperture using a dynamic mode AFM regulation method, being a second embodiment of the present invention. FIG. 3 is a schematic diagram of an apparatus for forming an aperture in a tip of a straight type optical fiber probe using shear force regulation, being a third embodiment of the present invention. FIG. 4 is a schematic diagram of an apparatus for forming an aperture in a tip of a straight type optical fiber probe using STM regulation, being a fourth embodiment of the present invention. FIG. 5 is a schematic diagram of an apparatus for forming an aperture in a tip of a cantilever having a microscopic aperture using evanescent light regulation, being a fifth embodiment of the present invention. FIG. 6 is a schematic diagram of an apparatus for forming an aperture in a tip of a straight type optical fiber probe using evanescent light regulation, being a sixth embodiment of the present invention. FIG. 7 is a schematic diagram of an apparatus for forming an aperture in a tip of a bent type optical fiber probe using a contact mode AFM regulation method, while estimating aperture size using light microscopy or light intensity from the aperture, being a seventh embodiment of the present invention. FIG. 8 is a force curve and a state diagram of contact mode ATM regulation. FIG. 9 is a force curve of dynamic mode ATM regulation. FIG. 10 is a force curve of shear force regulation. FIG. 11 is a graph showing a relationship between probe—sample distance and current value for STM regulation. FIG. 12 is a schematic diagram for describing an evanescent light regulation method. FIG. 13 is a schematic diagram for describing an evanescent light regulation method. FIG. 14 is a graph showing a relationship between probe—sample distance and evanescent light intensity for evanescent light regulation. FIG. 15 is a schematic diagram for describing an optical fiber probe production method used in the present invention. FIG. 16 is a schematic diagram for describing an cantilever production method used in the present invention. FIG. 17 is a schematic diagram for describing an aperture forming method for a cantilever having a microscopic aperture used in the present invention. FIG. 18 is a schematic diagram showing the angular relation between a longitudinal axis of the probe tip and a vertical axis extending from the surface of the sample. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The principal of the structure of and operation of the present invention will be described. In the following, the principal of operation of regulating a force on the probe tip will be described for each parameter. (1) When using atomic force (contact mode) This method uses the principle of a contact mode atomic force microscope (hereafter referred to as a contact mode AFM) using a bent type optical fiber probe and a cantilever with a microscopic aperture. FIG. 8 ( a ) shows a force curve in the case of the probe and the sample being brought into contact with each other, and FIG. 8 ( b ) is a drawing showing conditions between the probe and the sample corresponding to numbers in the force curve of FIG. 8 ( a ). In FIG. 8 ( a ), the horizontal axis represents a distance the sample has moved, and if it moves to the left, the sample approaches the probe. The vertical axis represents an amount of bending of the cantilever, with the upper side being a cantilever repulsion force acting, and the lower side being a cantilever attraction force acting. With a general contact mode AFM, an amount of bending of the cantilever is set, and a distance between the probe and the sample is feedback regulated so that the amount of bending is constant. The amount of bending is made to correspond to the force on the probe tip using hook's rule. Accordingly, by varying the bending amount parameter, as is clear from the force curve of FIG. 8 ( a ), the force on the probe tip inside a near field region where atomic force acts can be finely adjusted. Here, if the sample is a planar surface and the probe tip is flexible and a sphere having a radius of curvature R, then a relationship between a contact surface area A of the probe tip and a pressing force F on the probe tip is established as A=KF 2/3 R 2/3 (K is a constant) using the Hertz theory of elastic contact. At this time, if the tip is subjected to plastic deformation or breaking, a microscopic aperture having an aperture surface area of about A are formed. That is, an aperture having a desired diameter are formed by the pressing force. (2) When using atomic force (dynamic mode) This method also uses the principle of a dynamic mode atomic force microscope (hereafter referred to as a dynamic mode AFM) using a bent type optical fiber probe and a cantilever with a microscopic aperture. FIG. 9 shows a force curve in the case of bringing a probe close to a sample while vibrating the probe in a vertical direction within a plane orthogonal to the sample surface. The horizontal axis represents a distance between the probe and the sample, and movement to the left is when the sample and the probe are brought close together. The vertical axis represents an vibration attenuation factor with respect to an initial vibration amount of the cantilever, and when this is 0 the cantilever maintains a freely oscillating state with no attenuation, and when it is enters the negative side an external force acts on the probe and attenuation occurs. Here, of external forces causing vibration attenuation, one having the highest contribution factor is an atomic force when the probe and the sample are moved apart, but is an intermittent contact force to the sample surface when the probe and the sample are moved closer together. With a general dynamic mode AFM, the vibration attenuation factor is set, and the distance between the probe and the sample is feedback regulated so as to maintain vibration reduced by a constant amount from an initial vibration state. This attenuation factor corresponds to pressing force on the probe tip. Accordingly, by varying the attenuation factor parameters it is possible to finely adjust force on the probe tip within a near-field region where atomic force acts, as is clear from the force curve of FIG. 9 . A microscopic aperture having a desired diameter is formed by subjecting the probe tip to plastic deformation or breaking with the pressing force on the probe tip. With the dynamic AFM, it is also possible to take advantage of feedback using variation in phase of the cantilever, instead of the attenuation factor of the vibration. That is, if the distance between the probe and the sample is closed while exciting the cantilever at close to the resonant frequency, phase of vibration of the cantilever is varied by the external force acting on the probe tip. If the amount of variation in phase is set, it is possible to control the pressing force on the probe. tip in the same way as in when attenuation factor is a parameter, and as a result, an aperture having a desired diameter is formed by plastic deformation or breakage of the tip. (3) When using shear force This method is mainly used with straight type optical fiber probes. It is also possible to apply this method to bent type optical fiber probes and cantilevers with a microscopic aperture. Here, in the case of a straight type optical fiber probe, an amount of vibration of the probe is monitored, while in the case of a bent type optical fiber probe or a cantilever having a microscopic aperture a twisting angle is monitored. FIG. 10 shows a force curve in the case of bringing a probe and a sample together while vibrating the probe within a plane parallel to the sample surface. The horizontal axis represents a distance between the sample and the probe, with movement to the left being a condition of the probe and the sample approaching each other. The vertical axis represents a vibration attenuation factor compared to an initial vibration state of the optical fiber probe (or compared to vibration of the twisting angle in the case of a bent type optical fiber probe or a cantilever having a microscopic aperture), with 0 being a condition where a free vibration state is maintained and there is no vibration attenuation, while the negative side indicates that an external force is acting on the probe and vibration attenuation is occurring. Here, the external force causing vibration attenuation can be attributed to capillary force due to adsorbed water on the sample surface, frictional force between the probe and the sample, or an atomic force etc. With shear force regulation, a vibration attenuation factor is set, and a distance between the probe and the sample is feedback controlled so that vibration is held at an amplitude attenuated by a fixed amount from an initial state of oscillation. This attenuation factor corresponds to force acting on the probe tip. Components of this force are a shear force acting in the direction of vibration, the vibration force, and a pressing force acting in the vertical direction. As clearly shown in the force curve of FIG. 10, by varying the attenuation factor parameter it becomes possible to finely adjust the shear force on the probe tip within a near field region where the shear force acts, and the pressing force is also varied by change in the distance between the sample and the probe. A microscopic aperture having a desired diameter is formed by plastic deformation or breakage of the probe tip using these forces. In the case of shear force regulation, similarly to the dynamic mode AFM, instead of the vibration attenuation factor it is also possible to employ feedback using phase variation of the optical fiber probe or the cantilever having a microscopic aperture. Specifically, in the case of making a distance between the probe and the sample closer while exciting the optical fiber probe or the cantilever having a microscopic aperture close to the resonant frequency, phase of the vibration of the probe varies due to external force acting on the probe tip. If the amount of this phase variation is set, then similarly to the case where the attenuation factor is a parameter, it is possible to control the shear force and the pressing force on the probe tip, and as a result an aperture having a desired diameter is formed by plastic deformation or breakage of the tip. (4) When using tunnel current This method utilizes a scanning tunnel microscope (hereafter referred to as an STM) that uses straight type and bent type optical fiber probes having a conductive thin film formed on a tip and a cantilever having a microscopic aperture. FIG. 11 shows a relationship between a distance between a sample and a probe and a tunnel current value for conditions of a bias voltage applied between the probe and the sample. The horizontal axis represents the distance between the probe and the sample, with movement to the left indicating the probe and the sample being brought together. The vertical axis represents a tunnel current value. With STM control, a tunnel current value is set, and a distance between the probe and the sample is regulated so that the tunnel current value is held constant. If the distance between the probe and the sample is closed with the tunnel current value as a parameter, pressing force is produced on the probe tip by the interaction of atomic force, an absorption layer of the sample surface, a contamination layer etc. This pressing force increases as the distance between the probe and the sample becomes closer. Accordingly, as shown clearly in FIG. 11, by varying the tunnel current value parameter, the probe and the sample are brought close together and it becomes possible to finely adjust a pressing force on the probe tip within a near field region where the tunnel current is effective. A microscopic aperture having a desired diameter is formed by plastic deformation or breakage of the tip with this pressing force. (5) When using Evanescent light This method is used with straight and bent type optical fiber probes, and with cantilevers having a microscopic aperture. Method of performing evanescent light regulation cab be classified into {circle around (1)} methods for forming evanescent light on the sample surface, and {circle around (2)} methods of forming evanescent light on the probe tip. {circle around (1)} Methods for forming evanescent light on the sample side surface As shown in FIG. 12, in the case where light 102 is injected from a reverse side of a transparent sample 101 formed from a prism under total reflection conditions, an evanescent field 103 is formed at the sample surface. If a probe 104 is bright close to this evanescent field, evanescent light is scattered and converted to propagated light. The evanescent light strength is dependent on the distance from the sample surface. FIG. 14 shown a relationship between a probe—sample distance and scattering light intensity at this time. In FIG. 14, the horizontal axis represents a distance between the probe and the sample, with movement to the right being the condition where the probe and the sample are brought closer together. As will be understood from FIG. 14, the light intensity increases as the sample surface is approached. Accordingly, regulation of the distance between the probe and the sample becomes possible using the intensity of light scattered at the probe tip. If fine adjustment of the distance between the probe and the sample is made possible, an aperture is formed by plastic deformation or breakage of the tip, similarly to the case for STM regulation. {circle around (2)} methods of forming evanescent light on the probe tip As shown in FIG. 13, an aperture 202 that is smaller than a desired aperture is formed in advance on a tip of a probe 201 , and if light 203 is introduced into the aperture and evanescent field is formed in the probe tip (namely, the size of the aperture is smaller than the wavelength). In this state, if the probe 201 and the sample 205 are brought closer together, evanescent light is scattered at the sample surface and converted to propagation light. The evanescent light intensity is dependent on the distance from the aperture, and as shown in FIG. 14, light intensity increases as the sample surface is approached. Accordingly, it becomes possible to regulate the distance between the probe and the sample using the intensity of light scattered at the probe tip. If fine adjustment of the distance between the probe and the sample is made possible, an aperture is formed by plastic deformation or breakage of the probe tip, similarly to the case for STM regulation. In this method, in the state where the aperture is blocked off, after formation of an aperture by plastic deformation or breakage of the tip by bringing the probe into contact with the sample control is performed using the evanescent light from that aperture and it is possible to produce an aperture having the desired diameter. Embodiments of the present invention will now be described in the following, based on the drawings. FIG. 15 shows manufacturing processes up to before aperture formation using an optical fiber probe pressing method used in present invention. {circle around (1)} Sharpening Process Various methods have been proposed as processes for sharpening an optical fiber, but here a description will be given of a hot pulling method and an etching method as representative methods. A optical fiber sharpening process using the hot pulling method is shown in FIG. 15 ( al ). In the case of the hot pulling method, a laser beam 302 of a CO2 laser or the like is converged on an optical fiber 301 with tension on the optical fiber 301 . At this time, energy of the laser light is converted to heat energy at converged section, and localized fusion occurs. At this time, if more tension continues to be applied from the two ends of the optical fiber, the optical fiber is stretched to a pencil shape and finally ruptures. The shape of the rupture surface and the taper angle are adjusted by the intensity of the laser beam irradiated and the irradiation surface area and magnitude of the tension. Next, a description will be given of 2-phase etching, which is a typical example of a processes for sharpening using an etching method. As shown in FIG. 15 ( a 2 ), in the 2-phase etching process high concentration hydrofluoric acid solution 303 is used as etching fluid, and in order to prevent variations in concentration due to vaporization of the hydrofluoric acid, and to make the probe surface smooth at an interface, an organic solvent (heptane) 304 is deployed on the hydrofluoric acid solution, to give 2-phase conditions, and etching is carried out inside the hydrofluoric acid solution lower down than an interface between the two. The material of an optical fiber 305 is SiO 2 doped with GeO 2 for the core, and SiO 2 as the cladding. A ratio of the etching rates of the core and the cladding is varied by varying the mixing ratio of the etching fluid (mixing ratio of NH4F(50 weight %):HF(50 weight %):H 2 O) at this time, making it possible to control the taper shape and thickness of the taper section. The present invention is not limited to the above described hot pulling method and etching methods, and all generally used sharpening processes are included in the present invention. {circle around (2)} Bending Process (Bent Type Only) A bending process for a bent type optical fiber probe is shown in FIG. 15 ( b ). When making a bent type optical fiber probe, a laser beam 307 if a CO 2 laser or the like is condensed on the area around a tip of the sharpened optical fiber probe 306 . At the sections where the light is condensed SiO 2 is softened by the effect of heat energy, and the probe is bent by a difference in surface tension between the side where the laser beamed is condensed and the reverse side. When the bent type probe is used in AFM control, laser light strikes a normal probe back face and displacement of the probe is detected using an optical lever method. In order to produce a reflection surface for this laser light, as shown in FIG. 15 ( c ), a rear surface 306 a of the probe is mechanically ground by a grindstone 308 . {circle around (3)} Film Attaching Process In order to produce a microscopic aperture in the tip of an optical fiber probe with the method as shown in FIG. 15 ( d ), an Al film is vapor deposited. The sharpened optical fiber 309 is fixed in a vacuum evaporator, and Al is vapor deposited. At this time, the angle of attaching the probe with respect to the vapor deposition source 310 is set so that Al is not vapor deposited in the tip section, and the optical fiber probe is rotated to vapor deposit Al to the circumference of the tip section. Since the tip aperture section will be extended by force in a subsequent process, it is not necessary to make the aperture properly at this stage, and as long as the size of the aperture is smaller than the desired aperture diameter, there is no problem if part or all of the aperture is blocked up with a metallic film. Here, the metal used in film attaching is not limited to Al, and it is also possible to use a material such as Au or Cr etc. The film attaching method is also not limited to this method. Next, manufacturing processes before formation of the aperture using a method of pressing the cantilever having a microscopic aperture will be shown. {circle around (1)} Step of Manufacturing Cantilever with Probe Attached Various methods are used for manufacturing a cantilever with a probe attached, but here an embodiment of a method of manufacturing a silicon nitride type cantilever, which is a typical example, will be described. A method of manufacturing a silicon nitride film type cantilever used in the present invention is shown in FIG. 16 . As shown in FIG. 16 ( a ), a square cone shaped hole 401 a defining the shape of a probe section of the cantilever is formed on a silicon substrate 402 . Next, as shown in FIG. 16 ( b ), a silicon nitride type film 402 for producing the cantilever and the probe section is deposited on the silicon substrate. Next, as shown in FIG. 16 ( c ), this silicon nitride film is formed into a cantilever pattern 403 by selective etching in the shape of the cantilever. As shown in FIG. 16 ( d ), a support section 404 is then connected to the end of the cantilever. Finally, as shown in FIG. 16 (e), the silicon substrate 401 is removed by etching and the cantilever is produced. Besides this embodiment, as a cantilever it is also possible to use other forms of cantilever such as a cantilever made of a silicon film or a silicon oxide film, and all are included in the present invention {circle around ( 2 )} Hole Drilling Process Drilling of a hole in the cantilever 501 used in the present invention involves hanging the probe tip from a rear surface side of the cantilever, as shown in FIG. 17 ( a ), and forming a through hole 501 a through the probe tip along a longitudinal axis thereof disposed generally orthogonal to a longitudinal axis of the cantilever 501 using a focussed ion beam (FIB) 502 . The hole diameter at this time can be any size, but in this embodiment the diameter is made φ100 nm. The hole drilling process is not limited to FIB processing, and the present invention also includes methods such as electron beam processing or laser processing. {circle around ( 3 )} Film Attaching Process As shown in FIG. 17 ( b ), the cantilever in which a hole has been drilled is fixed in a vacuum evaporator, and an Al film 504 is vapor deposited. An attachment angle of the cantilever 501 with respect to the evaporation source 503 at this time is set so that Al is not vapor deposited on the tip section. In the case of the cantilever also, similarly to the optical fiber probe, since the tip aperture is flared out in a subsequent process, there is no need to strictly manufacture the aperture, and as long as the size of the aperture is smaller than the desired aperture diameter, there is no problem if part or all of the aperture section is blocked up with metallic film. The metal used for film attachment is not limited to Al, and any material such as Au or Cr can be used. Next, description will be given of a process of forming an aperture using a pressing method. FIG. 1 is a schematic diagram of an apparatus for forming an aperture in a tip of a bent type optical fiber probe using a contact mode AFM, being a first embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a sample 2 close to a probe 1 , a Z fine adjustment mechanism 4 a for finely adjusting a distance between the sample 2 and the probe 1 , an XY fine adjustment mechanism 4 b for scanning the sample 2 within a two-dimensional plane, a sample holder 5 for mounting a sample, a probe holder 5 for fixing the probe 1 , a displacement detection unit 6 for measuring an amount of displacement of the probe, and a control unit 7 for carrying out control of the overall system. Here, the coarse adjustment mechanism 3 uses a method for driving a feed screw with a motor, while the XY and Z fine adjustment mechanisms use a cylindrical piezoelectric element 4 . Also, displacement detection means applies a semiconductor laser 6 a to a reflection surface 1 a provided on a rear surface of the probe, and uses an optical head of an optical lever method for carrying out measurement of an amount of displacement of the probe using a four-piece detector 6 b. In a state where an aperture section 1 b of a bent type optical probe is pre-coated with an Al metal film and is almost completely blocked up, only a pin-hole that is smaller than the finally required fine aperture diameter (here φ50 nm) remains. Using this apparatus, the sample 2 is brought closer to the probe 1 using the coarse adjustment mechanism 3 while monitoring an amount of bending of the bent type optical fiber probe 1 . The sample 2 is brought up to a region where an atomic acts between the probe 1 and the sample 2 , and if the amount of bending becomes a previously set amount the coarse adjustment mechanism 3 is stopped, and feedback is carried out using the Z fine adjustment mechanism 4 a so that this amount of bending becomes constant. A pressing force received by the probe tip at an initial value for this amount of bending is a force that will not break the tip. After that, a bending amount parameter of the control unit is changed, and the distance between the sample and the probe is made gradually closer using the Z fine adjustment mechanism 4 a, increasing the pressing force on the tip, thus breaking the tip and forming the aperture. In this embodiment, since a relationship between the aperture diameter and the bending amount is quantified in advance through experimentation, it is possible to form an aperture having any diameter by setting the bending amount. The method of using the bending amount as a parameter in this method can also be applied to a cantilever having a microscopic aperture. FIG. 2 is a schematic diagram of an apparatus for forming an aperture in a tip of a cantilever having a microscopic aperture using dynamic mode AFM, being a second embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a sample 11 close to a probe 10 a, a Z fine adjustment mechanism 4 a for finely adjusting a distance between the sample 11 and the probe 10 a, an XY fine adjustment mechanism 4 b for scanning the sample 1 within a two-dimensional plane, a sample holder 15 for mounting the sample 1 , a cantilever holder 13 having a piezoelectric element 12 for vibrating the cantilever attached, a vibration detection unit 6 for measuring an amount of vibration of the cantilever, and a control unit 14 for carrying out control of the overall system. Here, the coarse adjustment mechanism 3 uses a method for driving a feed screw with a motor, while the XY and Z fine adjustment mechanisms use a cylindrical piezoelectric element 4 . Also, vibration detection means applies a semiconductor laser 6 a to a reflection surface 10 b provided on a rear surface of the cantilever, and uses an optical head 6 of an optical lever method for carrying out measurement of an amount of vibration of the cantilever using a four-piece detector 6 b. The cantilever having a microscopic aperture 10 has a hole formed in advance in the probe section by FIB processing, but the tip aperture section 10 c is initially blocked up with an Al metallic film. Using this apparatus, the cantilever 10 is vibrated at close to the resonant frequency and the sample 11 is brought closer to the probe 10 a by the coarse adjustment mechanism 3 while monitoring an amount of vibration. The sample 11 is brought up to a region where an atomic acts between the probe 10 a and the sample 11 , and if the vibration is attenuated to a previously set amount the coarse adjustment mechanism 3 is stopped, and feedback is carried out using the Z fine adjustment mechanism 4 a so that this amount of vibration becomes constant. A pressing force received by the probe tip at an initial value for this amount of vibration is a force that will not break the tip. After that, a vibration attenuation factor parameter of the control unit 14 is changed, and the distance between the sample and the probe is made gradually closer using the Z fine adjustment mechanism 4 a, increasing the pressing force on the tip, thus breaking the tip and forming the aperture. In this embodiment also, since a relationship between the aperture diameter and the vibration attenuation factor is quantified in advance through experimentation, it is possible to form an aperture having any diameter by setting the vibration attenuation factor. In this embodiment, a vibration attenuation factor has been used as a parameter for controlling a distance between the probe and the sample, but it is also possible to consider a method of performing control using a variation in phase. A control method using a dynamic mode AFMM can also be applied to a straight type optical fiber probe. FIG. 3 is a schematic diagram of an apparatus for forming an aperture in a tip of a straight type optical fiber probe using shear force regulation, being a third embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a sample 21 close to a probe 20 , a Z fine adjustment mechanism 4 a for finely adjusting a distance between the sample 21 and the probe 20 , an XY fine adjustment mechanism 4 b for scanning the sample 21 within a two-dimensional plane, a sample holder 26 for mounting the sample, a probe holder 23 to which a piezoelectric element 22 for probe excitation is attached, a vibration detection unit 24 for measuring an amount of vibration of the probe 20 , and a control unit 25 for carrying out control of the overall system. Here, the coarse adjustment mechanism 3 uses a method for driving a feed screw with a motor, while the XY and Z fine adjustment mechanisms use a cylindrical piezoelectric element 4 . Also, the vibration detection means has the probe 20 fastened to piezoelectric body 24 a, and employs a method for measuring vibration amount by converting variation in force acting on the probe tip to variation in an amount of electrical charge of the piezoelectric body. In a state where an aperture section 20 a of an optical fiber probe is pre-coated with an Al metallic film and is almost completely blocked up, only a pin-hole that is smaller than the finally required fine aperture diameter (here φ50 nm) remains. Using this apparatus, the probe 20 is vibrated at close to the resonant frequency within a plane parallel to the sample, and the sample 21 is brought closer to the probe 20 by the coarse adjustment mechanism 3 while monitoring an amount of vibration. The sample 21 is brought up to a region where a shear force acts between the sample 21 and the probe 20 , and if the vibration is attenuated to a previously set amount the coarse adjustment mechanism 3 is stopped, and feedback is carried out using the Z fine adjustment mechanism 4 a so that this amount of vibration becomes constant. A pressing force and shear force received by the probe tip at an initial value for this amount of vibration are forces that will not break the tip. After that, a vibration attenuation factor parameter of the control unit is changed, and the distance between the sample and the probe is made gradually closer using the Z fine adjustment mechanism 4 a, increasing the pressing force and the shear force on the tip, thus breaking the tip and forming the aperture. In this embodiment also, since a relationship between the aperture diameter and the vibration attenuation factor is quantified in advance through experimentation, it is possible to form an aperture having any diameter by setting the vibration attenuation factor. In this embodiment, a vibration attenuation factor has been used as a parameter for controlling a distance between the probe and the sample, but it is also possible to consider a method of performing control using a variation in phase. As the method for detecting vibration amount, besides the piezoelectric method it is also possible to use a method for optically measuring vibration amount using a laser. Also, shear force control is not limited to a straight type optical fiber probe, and can also be applied to a cantilever having a microscopic aperture or a bent type optical fiber probe. In such cases, the cantilever or bent type probe is twistingly vibrated so that the tip section of the cantilever or probe tip vibrates within a plane parallel to the sample. At this time, an amount of variation in the twisting angle is monitored using a force on the probe tip. This twisting angle corresponds to vibration amount in the case where a straight type optical fiber probe is used, and enables control of the distance between the probe and the sample. Accordingly, it is possible to form a microscopic aperture in the probe tip using the same principal as in the third embodiment. FIG. 4 is a schematic diagram of an apparatus for forming an aperture in a tip of a straight type optical fiber probe using STM regulation, being a fourth embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a conductive sample 31 close to a probe 30 , a Z fine adjustment mechanism 4 a for finely adjusting a distance between the sample 31 and the probe 30 , an XY fine adjustment mechanism 4 b for scanning the sample 31 within a two-dimensional plane, a conductive sample holder 36 for fixing the conductive sample 31 , a probe holder 32 for fixing the sample, a voltage applying unit 33 for applying a bias voltage between the probe 30 and the sample 31 , current measuring means 34 for measuring a tunnel current flowing between the probe 30 and the sample 31 , and a control unit 35 for carrying out control of the overall system. Here, the coarse adjustment mechanism 3 uses a method for driving a feed screw with a motor, while the XY and Z fine adjustment mechanisms use a cylindrical piezoelectric element 4 . Also, the sample 31 is a Au coated glass to give a sample having conductivity, and the bias voltage is applied to the sample holder through the sample holder 36 . The entire probe body, including the probe tip section, is coated in an Au metallic film, and the aperture section is almost completely blocked up. Since the probe itself is also covered with the conductive film, a tunnel current flows between the probe 30 and the sample 31 to bring the two together. Using this apparatus, the sample 31 is brought closer to the probe 30 by the coarse adjustment mechanism 3 while monitoring an amount of current. The sample 31 is brought up to a region where a tunnel current flows between the sample 31 and the probe 30 , and if the tunnel current value becomes a previously set amount the coarse adjustment mechanism 3 is stopped, and feedback is carried out using the Z fine adjustment mechanism 4 a so that this tunnel current value becomes constant. A pressing force received by the probe tip at an initial value for this tunnel current is a force that will not break the tip. After that, a tunnel current parameter of the control unit 35 is changed, and the distance between the sample 31 and the probe 30 is made gradually closer using the Z fine adjustment mechanism 4 a, increasing the pressing force on the tip, thus breaking the tip and forming the aperture 30 a. In this embodiment also, since a relationship between the aperture diameter and the tunnel current value is quantified in advance through experimentation, it is possible to form an aperture having any diameter by setting the tunnel current value. A control method using STM can also be applied to a bent type optical fiber probe or a cantilever having a microscopic aperture having a conductive metal film formed on a tip. FIG. 5 is a schematic diagram of an apparatus for forming an aperture in a tip of a cantilever having a microscopic aperture using evanescent light regulation, being a fifth embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a prism 41 used as a sample close to a probe 40 a, a Z fine adjustment mechanism 4 a for finely adjusting a distance between the prism 41 and the probe 40 a, an XY fine adjustment mechanism 4 b for scanning the prism 41 within a two-dimensional plane, a cantilever holder 42 for fixing a cantilever 40 , a laser optical system constructed so as to irradiate laser light under total reflection conditions from the underneath of the prism 41 , a light detection unit 44 for detecting the intensity of light scattered at the cantilever tip, and a control unit 45 for carrying out control of the overall system. Here, the coarse adjustment mechanism 3 uses a method for driving a feed screw with a motor, the XY and Z fine adjustment mechanisms use a cylindrical piezoelectric element 4 , and the light detection unit 44 uses a photomultiplier 44 a. The cantilever having a microscopic aperture 40 has a through hole formed in advance in the probe section using FIB processing, but the tip aperture section 4 b is initially blocked up by coating with an Al metallic film. Using this apparatus, when forming the aperture, a laser beam is irradiated under total reflection conditions from underneath the prism 41 and an evanescent field is formed on the surface of the prism. Next, the prism 41 is brought closer to the probe 40 a by the coarse adjustment mechanism 3 . If the probe 40 a is brought up to an evanescent region evanescent light is scattered at the probe tip and converted to propagation light. This propagation light is converged by a converging lens 46 provided diagonally above the regions where the evanescent field is generated and light intensity is measured using a photomultiplier 44 a. Since evanescent light intensity depends on the distance from the prism surface, if feedback is carried until the intensity of this scattered light becomes constant, it is possible to regulate the distance between the probe and the prism surface. If the scattered light intensity becomes a value set in advance, the coarse adjustment mechanism 3 is stopped, and feedback is carried out using the Z fine adjustment mechanism 4 a so that this scattered light intensity becomes constant. A pressing force received by the probe tip at an initial value for this scattered light intensity is a force that will not break the tip. After that, a scattered light intensity parameter of the control unit is changed, and the distance between the probe 40 a and the prism 41 is made gradually closer using the Z fine adjustment mechanism 4 a, increasing the pressing force on the tip, thus breaking the tip and forming the aperture. In this embodiment also, since a relationship between the aperture diameter and the scattered light intensity is quantified in advance through experimentation, it is possible to form an aperture having any diameter by setting the scattered light intensity. Control using evanescent light can also be applied to a bent type optical fiber probe or a straight type optical fiber probe. It is also possible to consider a method in which scattered light detection is performed by converging light that has been converged at the probe tip at the probe aperture, and detecting the intensity of light propagated through the optical fiber at the end of the optical fiber. FIG. 6 is a schematic diagram of an apparatus for forming an aperture in a tip of a straight type optical fiber probe using evanescent light regulation, being a sixth embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a sample 51 close to a probe 50 , a Z fine adjustment mechanism 4 a for finely adjusting a distance between the sample 51 and the probe 50 , an XY fine adjustment mechanism 4 b for scanning the sample 51 within a two-dimensional plane, a sample holder 56 for mounting a sample, a probe holder 52 for fixing the probe 50 , a laser optical system 53 for irradiating laser light to an optical fiber probe, a light detection unit 54 for detecting the intensity of scattered light, and a control unit 55 for carrying out control of the overall system. Here, the coarse adjustment mechanism 3 uses a method for driving a feed screw with a motor, the XY and Z fine adjustment mechanisms use a cylindrical piezoelectric element 4 , and the light detection unit 54 uses a photomultiplier 54 a. In a state where an aperture section 50 a of the optical fiber probe is pre-coated with an Al metallic film and is almost completely blocked up, only a pin-hole that is smaller than the finally required fine aperture diameter (here φ50 nm) remains. Using this apparatus, when forming the aperture, a laser beam is converged by a converging lens 58 , is incoming from an end 50 b of the optical fiber probe, and an evanescent field is formed in the vicinity of a microscopic aperture 50 a provided in the probe tip. Next, the sample 51 is brought closer to the probe 50 by the coarse adjustment mechanism 3 . If the sample 51 approached the tip of the probe 50 , evanescent light is scattered at the sample surface and converted to propagation light. This propagation light is converged by a converging lens 57 provided diagonally above the probe tip, and light intensity is measured using the photomultiplier 54 a. Since evanescent light intensity depends on the distance from the sample surface, if feedback is carried until the intensity of this scattered light becomes constant, it is possible to regulate the distance between the probe and the sample surface. If the scattered light intensity becomes a value set in advance, the coarse adjustment mechanism is stopped, and feedback is carried out using the Z fine adjustment mechanism 4 a so that this scattered light intensity becomes constant. A pressing force received by the probe tip at an initial value for this scattered light intensity is a force that will not break the tip. After that, a scattered light intensity parameter of the control unit is changed, and the distance between the probe 50 and the sample 51 is made gradually closer using the Z fine adjustment mechanism 4 a, increasing the pressing force on the tip, thus flaring the tip outwards and forming an aperture having a desired diameter. In this embodiment also, since a relationship between the aperture diameter and the scattered light intensity is quantified in advance through experimentation, it is possible to form an aperture having any diameter by setting the scattered light intensity. This method is also applicable to a bent type optical fiber probe or a cantilever having a microscopic aperture. FIG. 7 is a schematic diagram of an apparatus for forming an aperture in a tip of a bent type optical fiber probe using contact mode AFM regulation, while estimating aperture size using light microscopy or light intensity from the aperture, being a seventh embodiment of the present invention. This apparatus comprises a coarse adjustment mechanism 3 for bringing a sample 61 close to a probe 60 , a Z fine adjustment mechanism 68 a for finely adjusting a distance between the sample 61 and the probe 60 , an XY fine adjustment mechanism 68 b for scanning the sample within a two-dimensional plane, a sample holder 71 for mounting the sample, a probe holder 75 for fixing the probe 60 , a displacement detection unit 6 for measuring an amount of displacement of the probe, control unit 70 for controlling the overall system, and an inverting microscope 76 capable of observing a sample surface from a lower side of the sample. At this time, the sample 61 is observable by a CCD camera 63 through an optical system having an objective lens 62 of transparent glass arranged below the sample and comprising a mirror 72 totally reflecting an image of the probe tip 60 a, an image lens 73 and a half mirror 64 , and a light path is divided into two by the half mirror 64 giving a structure capable of measuring light intensity using a photomultiplier 65 . Also, the Z fine adjustment mechanism 68 a and the XY fine adjustment mechanism 68 b used are made up of three cylindrical piezoelectric elements 68 arranged so as to surround the objective lens 62 , and the sample holder 71 provided on these cylindrical piezoelectric elements is caused to move by driving them in the same direction. Using this apparatus, light of the laser optical system 69 is converged by the converging lens 74 , and is incident on the probe tip 60 b. With the focal point of the objective lens 62 aligned with the sample surface by a focussing mechanism 66 , the sample 61 is brought close to the probe 60 by the coarse adjustment mechanism 3 , and if it reaches a region where an atomic force acts, the aperture shape is observed n a monitor 67 using the image of the CCD camera 63 . At the same time, evanescent light formed at the probe tip 60 a scatters at the sample surface, light that has passed through the sample 61 is converged by the objective lens 62 and light intensity is measured using the photomultiplier 65 . An amount of bending of the probe at this time is measured by an optical head 6 using an optical lever method, and with the amount of bending as a parameter the amount of bending is increased further by the control unit 70 while performing feedback using the Z fine adjustment mechanism 68 a, and if a pressing force of the probe tip increases the tip aperture 60 a is flared outwards by plastic deformation or breakage. The aperture diameter at this time can be estimated by monitoring light leaking out from the tip using the image of the CCF camera, or by measuring light intensity the photomultiplier 65 , and the bending amount is increased until an aperture of a desired diameter are obtained. This method is not limited to the case of making the bending amount a parameter, and can also be applied to other distance regulating methods. It can also be applied to a straight type optical fiber probe. FIG. 18 is a schematic view showing a preferred angular relation between a longitudinal axis A of a probe tip 600 and a vertical axis B extending from the surface of a sample 700 in the methods of forming an aperture in the optical fiber probe according to the foregoing embodiments of the present invention. Preferably, the longitudinal axis A is inclined less than 45° from the vertical axis B. It is also possible to make an aperture for a cantilever using the previously described methods, taking light intensity using the image from a CCD camera or a photomultiplier as a criterion. In this case, introduction of laser light involves an objective lens arranged on an upper side of the cantilever, and light is converged in an aperture opened in the cantilever from a rear surface. It is also possible to apply a method where a light waveguide is formed on the cantilever, laser light is coupled into the light waveguide at an optical fiber or an objective lens, and light is guided into the aperture. As described above the present invention brings a probe tip and a sample close together or into contact with each other using an atomic force or a shear force acting between the probe tip of an optical fiber probe or a cantilever having a microscopic aperture, or tunnel current or evanescent light, controls a force acting on the tip with one of these physical amounts as a parameter, and forms an aperture in the optical fiber probe or cantilever having a microscopic aperture using means for subjecting the probe tip to plastic deformation or breakage using a force from the sample surface to make an aperture of a desired diameter in the tip section. By using this type of method, it is no longer necessary to optimize vapor deposition conditions as was the case when forming an aperture through vapor deposition in the related art, and even if the type or shape of optical fiber probe or cantilever having a microscopic aperture is varied it is possible to form an aperture with good reproducibility. Also, it is possible to correct the aperture diameter after aperture formation. Still further, in the case of forming an aperture by pressing the probe of an optical fiber probe or cantilever having a microscopic aperture against a sample, it is possible to adjust the pressing force more finely than in the related art, and problems such as the aperture diameter being too large and the shape of the aperture becoming elliptical can be alleviated, and it is possible to easily form the aperture.
A method of forming an aperture in an optical fiber probe comprising the steps of sharpening the tip and bending the tip section of the optical fiber probe relative to a longitudinal axis, covering a portion of the probe with a metallic film, positioning the probe relative to a surface of a sample, effecting relative movement between the probe and the surface of the sample so that the probe is disposed in a region where an atomic force acts between the probe and the surface of the sample, measuring and monitoring a displacement of the probe resulting from the atomic force acting between the tip of the probe and the surface of the sample, using a pressing force from the atomic force to plastically deform or break the tip section of the probe to form an aperture in the tip section having a diameter obtained in accordance with a measured value of the displacement of the probe.
8
REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to German Patent Application No. 10 2005 051 065.5-33, filed on Oct. 25, 2005. BACKGROUND [0002] Electrical circuits that are fabricated on semiconductor wafers can include a plurality of voltage domains. A voltage domain is an electrical circuit or circuit block that operates at a specific supply voltage value. The supply voltages for circuits that are used in mobile terminal devices are typically derived from a battery voltage. The supply voltage for a voltage domain is usually connected by means of a switching unit that is arranged outside of a semiconductor device. For this purpose, a voltage source such as a battery that provides the supply voltage is coupled to a supply connection or a supply pin of the semiconductor device via the switching unit. The supply connection is connected to a voltage network within the semiconductor device and forms a voltage domain. The supply connection is connected to or isolated from the voltage source in accordance with a switching state that is selected for the switching unit. If the supply connection is connected to the voltage source, the supply voltage is present at the voltage domain. [0003] In typical systems, a control signal for connecting or disconnecting the supply voltage from a voltage domain is generated within the semiconductor device. In order to control the switching unit by means of the control signal, a control connection or control pin to pass the control signal to the switching unit is provided at the semiconductor device. As a result, at least two connections are needed at the semiconductor device for each voltage domain. The number of connections or pins available for a semiconductor device can be limited as typically many connections are required for other functions. As a result, a disadvantage of this approach is that only a limited number of voltage domains may be able to be provided within the semiconductor device. [0004] It is known to provide a switching unit with respect to each voltage domain within the semiconductor device. The respective switching unit enables the supply voltage to be disconnected from or connected to the voltage domain. The switching unit is typically implemented as a switching element that is large in relation to other circuits that are used in the semiconductor device in order to drive large currents without significant voltage drops at the voltage domains. Furthermore, the switching element is typically located within regions of the semiconductor device or circuit that are not fabricated by means of standard cells. As a result, the length of a supply line between a switching element and a voltage domain may result in a significant voltage drop across the supply line. [0005] In order to avoid the voltage drops, the large switching element is often implemented with multiple switching elements that are relatively smaller in size. The smaller switching elements can be designed and implemented as standard cells. A number of switching elements can be connected in parallel in order to meet the current demands of a voltage domain. [0006] A plurality of voltage domains are usually coupled to voltage supply. When a connection is first made to a first voltage domain, current flows that initially charges the gates and/or other capacitances of circuits within the first voltage domain. This connection operation can initially give rise to a relatively large change in a current I SUP supplied by the voltage supply. The supply lines arranged between the voltage supply and the voltage domain typically have an inductance L. As a result of this inductance, a change in the current I SUP causes a voltage drop ΔU SUP that occurs along the supply lines in accordance with Equation (1). Δ ⁢   ⁢ U SUP = L ⁢ ⅆ I SUP ⅆ t + RI SUP . ( 1 ) [0007] A non-reactive resistance R that is present in the supply lines is also taken into account by Equation (1). [0008] In most cases, at least one second voltage domain is connected to a supply line and a same supply voltage is provided to the first and second voltage domains. If the second voltage domain is already in an operating state when the first voltage domain is switched on, the voltage drop ΔU SUP may be large enough to result in a local malfunction within the second voltage domain. The local malfunction can lead to a global malfunction of the entire semiconductor device. The occurrence of a global malfunction is often times not immediately evident to a user of the semiconductor device. [0009] For these and other reasons, there is a need for the present invention. SUMMARY [0010] One embodiment of the invention provides a circuit. The circuit includes a switching unit configured to connect or disconnect a voltage domain to a supply voltage input. The switching unit includes a first switch, a second switch and a third switch. The circuit includes a control signal input configured to receive a switch control signal. The circuit includes a signal distribution unit that is configured to output the switch control signal to the first switch delayed by a first time interval and to output the switch control signal to the second switch and to the third switch delayed by a second time interval. BRIEF DESCRIPTION OF THE DRAWINGS [0011] Embodiments of the invention will be explained in detail in the following text with reference to the accompanying drawings, in which: [0012] FIG. 1 illustrates one embodiment of a voltage supply of a semiconductor circuit with two voltage domains. [0013] FIG. 2 illustrates a first embodiment of a switching unit in a voltage supply. [0014] FIG. 3 illustrates a second embodiment of a switching unit in a voltage supply. [0015] FIG. 4 illustrates a third embodiment of a switching unit in a voltage supply. [0016] FIG. 5 illustrates a fourth embodiment of a switching unit in a voltage supply. [0017] FIG. 6 illustrates a fifth embodiment of a switching unit in a voltage supply. DETAILED DESCRIPTION [0018] FIG. 1 illustrates one embodiment of a voltage supply of a semiconductor circuit with two voltage domains. The voltage supply has a first input 101 , at which a first supply potential, a ground potential, or a reference potential may be provided. In some embodiments, the supply potential can be provided by a voltage source such as a battery, which is not illustrated in FIG. 1 . [0019] The voltage supply has a second input 102 , at which a second supply potential may be provided. In one embodiment, the second supply potential is a bias voltage. The first input 101 is coupled via a first supply line 103 to a first voltage domain 104 (illustrated by broken lines) and a second voltage domain 105 (illustrated by broken lines). A supply voltage of the two voltage domains results from the difference between the first supply voltage potential and the second supply voltage potential. On account of physical properties, in various embodiments, the first supply line has a first inherent inductance 106 and a first non-reactive resistance 107 . The second input 102 is coupled via a second supply, line 108 to the first voltage domain 104 and the second voltage domain 105 . On account of physical properties, in various embodiments, the second supply line 108 has a second inherent inductance 109 and a second non-reactive resistance 110 . The second supply line 108 connects to the first voltage domain 104 via a switching unit 111 . [0020] In the illustrated embodiment, the second supply voltage potential may be provided to the first voltage domain 104 by means of the switching unit 111 . The switching unit 111 is coupled to a control unit 112 . In various embodiments, the control unit 112 regulates a switching state of switching unit 111 by means of a control signal. In the event of an operation to connect the supply voltage to the first voltage domain 104 , the second supply voltage potential is provided to the first voltage domain 104 by means of the switching unit 111 . As a result, a current flows through the first supply line 103 and through the second supply line 108 . In various embodiments, these currents charge various elements within the first voltage domain 104 that include, but are not limited to, MOSFET (metal-oxide semiconductor field-effect transistor) gates and/or other intrinsic capacitances. A change in the currents can result in voltage drops in the first supply line 103 on account of the first inherent inductance 106 and in the second supply line 108 on account of the second inherent inductance 109 . The induced voltage drops may lead to a decrease in the voltage supplied to the second voltage domain 105 , with the result that a malfunction of the semiconductor circuit may occur. [0021] FIG. 2 illustrates a first embodiment of a switching unit in a voltage supply. The switching unit 201 has a control signal input 202 that receives a control signal. In some embodiments, the control signal is provided by a control unit as shown in FIG. 1 . In the illustrated embodiment, the control input 202 is coupled to an input of a first delay element 203 . An output of the first delay element 203 is coupled to a first switching element 205 in order to regulate the switching state of the first switching element 205 . The output of the first delay element 203 is coupled to an input of a second delay element 204 . The first switching element 205 is coupled between a third supply line 207 and a fourth supply line 208 . In one embodiment, if the first switching element 205 is in a closed switching state, equalization current may flow between the third supply line 207 and the fourth supply line 208 until the potential in both supply lines match. In one embodiment, the third supply line 207 may correspond to the second supply line 108 shown in FIG. 1 . [0022] In the illustrated embodiment, an output of the second delay element 204 is coupled to the input of a third delay element 206 and is also coupled to a second switching element 210 in order to define the switching state of the second switching element 210 . The output of the third delay element 206 is coupled to a third switching element 211 and is also coupled via none or one or more further delay elements to a fourth delay element 209 (illustrated by dashes). An output of the fourth delay element 209 is coupled to a fourth switching element 213 . The input of the fourth delay element 209 is coupled to the input of a fifth delay element 212 . The output of the fifth delay element 212 is coupled to a sixth switching element 214 . [0023] The second switching element 210 , the third switching element 211 , the fourth switching element 213 and the fifth switching element 215 are each coupled between the third supply line 207 and the fourth supply line 208 , so that in a closed switching state each switching element connects the third supply line 207 to the fourth supply line 208 . In one embodiment, if one of the switching elements is in a closed switching state, the potentials on the first supply line 207 and the second supply line 208 are the same. In some embodiments, an implementation uses a number of standard cells that each comprise a delay element, an individual element, or both a delay element and an individual element. In some embodiments, the delay elements comprise inverter elements. In the illustrated embodiment, delay elements such as the first delay element 203 and the second delay element 204 include a series circuit that comprises two inverter elements. In this embodiment, the polarity of the control signal is not altered by a delay element. In one embodiment, the switching elements may be realized as n-MOS transistors or p-MOS transistors. [0024] In the illustrated embodiment, the implementation of the switching unit 201 allows for carrying out the connection of a voltage domain progressively. In one embodiment, the control signal closes a switching element having a high voltage potential, that is to say, logic “1”. In the event of a switch-on operation, the control signal provided at the control input closes the first switching element 205 . After a time delay defined by the second delay element 204 , the control signal reaches the control input of the second switching element 210 and closes the second switching element 210 . In this embodiment, the first switching element 205 is closed, the second switching element 210 is closed after the first switching element 205 is closed, and the third switching element 211 is closed after the second switching element 210 is closed. The fourth switching element 213 and the fifth switching element 214 are closed simultaneously after the third switching element 211 is closed. [0025] In the illustrated embodiment, at each point in time after the beginning of the switch-on operation, the control signal is present at a defined number of individual elements that are closed. The number of closed switching elements limits the flow of an equalization current between the first supply line 207 and the second supply line 208 . In this embodiment, a temporal change in the switch-on current is limited. The number of closed switching elements defines the maximum switch-on current by the sum of the saturation currents of the closed switching elements. In other words, only a current driven by the closed switching elements will flow. The temporal sequence of the closing of the switching elements likewise limits the maximum change in the switch-on current over time. As a consequence, an excessively large voltage drop is prevented from arising in the leads of the voltage supply. [0026] In one embodiment, a rapid connection or disconnection of the voltage domain to the voltage supply can occur. In this embodiment, frequent disconnection and connection of the voltage supply may provide for an energy savings potential in the case of the supply voltage. The energy savings potential can be particularly advantageous for battery-powered systems, such as portable computers, mobile phones or mobile terminal devices. [0027] FIG. 3 illustrates a second embodiment of a switching unit in a voltage supply. The same reference symbols or numerals are used for similar elements of the various embodiments. The switching unit 301 includes a control input 202 to receive a control signal. In one embodiment, the control signal may be provided by a control unit as shown in FIG. 1 . In the illustrated embodiment, the control input 202 is coupled to an input of a first delay element 203 . The control input is likewise coupled to the input of a second delay element 204 . An output of the first delay element 203 is coupled to a first switching element 205 . The output of the second delay element 204 is coupled to a second switching element 210 . The output of the second delay element 204 is coupled to the input of a third delay element 206 . The first switching element 205 and the second switching element 210 are coupled in series between a third supply line 207 and a fourth supply line 208 . If the first switching element 205 and the second switching element 210 are in a closed switching state, an equalization current flows between the third supply line 207 and the fourth supply line 208 until the respective potentials are equal. The current flowing through the first switching element 205 and the second switching element 210 is limited by the respective saturation currents of the first switching element 205 and the second switching element 210 . In one embodiment, the higher resistance that results from the first switching element 205 and the second switching element 210 being coupled in series results in a reduced current flowing through switching elements 205 and 210 . [0028] In the illustrated embodiment, an output of the third delay element 206 is coupled to a third switching element 211 . The output of the third delay element 206 is likewise coupled via none or one or more further delay elements to a fourth delay element 209 (illustrated by dashes). An output of the fourth delay element 209 is coupled to a fourth switching element 213 and to the input of a fifth delay element 212 . An output of the fifth delay element 212 is coupled to a sixth switching element 214 . [0029] In the illustrated embodiment, the third switching element 211 , the fourth switching element 213 and the fifth switching element 214 are arranged between the third supply line 207 and the fourth supply line 208 , so that each switching element in a closed switching state connects the third supply line 207 to the fourth supply line 208 . If one of the switching elements is in a closed switching state, the potentials on the first supply line 207 and the second supply line 208 will equalize. In one embodiment, the switching elements may be implemented as n-MOS transistors or p-MOS transistors. [0030] In the illustrated embodiment, a switch-on operation takes place in a manner analogous to that in FIG. 2 . In this embodiment, the first switching element 205 and the second switching element 210 are closed simultaneously. The current that flows through the series circuit comprising the two switching elements is lower than a current that would flow through a single switching element, such as, for example, the third switching element 211 , the fourth switching element 213 or the fifth switching element 214 . In this embodiment, the lower initial current limits a temporal change in the current flow. In this embodiment, the limited change in the current flow enables the voltage domain that is coupled to the switching unit to be switched on as rapidly as possible while ensuring the functioning of the remaining circuit domains. In various embodiments, the switching elements illustrated in FIG. 3 can be implemented using standard cells. [0031] FIG. 4 illustrates a third embodiment of a switching unit in a voltage supply. The same reference symbols or numerals are used for similar elements of the various embodiments. The switching unit 401 shown in FIG. 4 has a control input 202 to receive a control signal. In various embodiments, the control signal may be provided, as in FIG. 2 , by means of a control unit as shown in FIG. 1 . The control input 202 is coupled to an input of a first delay element 203 , and an output of the first delay element 203 is coupled to an input of a second delay element 204 . In addition, the output of the first delay element 203 is coupled to a first switching element 205 . As a result, the first switching element can be put into a closed switching state or an open switching state by means of the control signal. [0032] In the illustrated embodiment, an output of the second delay element 204 is coupled to a second switching element 210 , a third switching element 211 and to an input of a fourth delay element 209 . An output of the fourth delay element 209 is coupled to a fourth switching element 213 , to a fifth switching element 214 and the input of a fifth delay element 212 . An output of the fifth delay element 212 is coupled to a sixth switching element 216 . [0033] In the illustrated embodiment, the first switching element 205 , the second switching element 210 , the third switching element 211 , the fourth switching element 213 , the fifth switching element 214 and the sixth switching element 216 are each coupled between a third supply line 207 and a fourth supply line 208 . Each of the switching elements when in a closed switching state electrically couples the third supply line 207 to the fourth supply line 208 . In one embodiment, this enables the potential on the supply lines to be equalized [0034] In the illustrated embodiment, a switch-on operation of the switching unit shown in FIG. 4 is effected in such a way that the first switching element 205 is closed first. As a result, an electrical current flows between the third supply line 207 and the fourth supply line 208 as a result of a potential difference. The current is restricted by the saturation current or the internal resistance of the first switching element 205 . If the first switching element 205 is embodied as field effect transistor, this restriction also results from a channel length or channel width of a gate region of the field-effect transistor. [0035] In the illustrated embodiment, the second delay element 204 delays the propagation time of the control signal by a predetermined time interval, after which the second switching element 210 is closed. In one embodiment, the second switching element 210 drives a higher current for equalizing the potentials on the third supply line 207 and the fourth supply line 208 . In one embodiment, the second switching element 210 has a higher saturation current or a lower internal resistance as compared to the first switching element 205 . [0036] In the illustrated embodiment, the third switching element 211 and the second switching element 210 are closed simultaneously. The fourth switching element 213 is subsequently closed after a time interval determined by the third delay element 209 . [0037] The fifth switching element 214 is closed together with the fourth switching element 213 . The sixth switching element 216 is subsequently closed after a time interval determined by the fourth delay element 209 . [0038] In the illustrated embodiment, the switching elements are arranged in pairs. Thus, the first switching element 205 is arranged spatially in proximity to the second switching element 210 . The third switching element 211 is arranged spatially in proximity to the fourth switching element 213 . The fifth switching element 214 is arranged spatially in proximity to the sixth switching element 216 . Each switching element pair includes one switching element driving a low current and one switching element driving a higher current. The pairs may be distributed spatially over the voltage domain. In this embodiment, a specific switch on operation may be applied. In one embodiment, a switching element that can drive a low current for pre-charging an environment is closed first, and a switching element that drives a higher current is closed later for faster charging. [0039] In various embodiments, to accelerate the overall charging operation, a “weaker” switching element of a different switching element pair, which can already pre-charge a different environment in the voltage domain, is already closed with the “stronger” switching element. If the second switching element 210 and the first switching element 205 are implemented as field effect transistors, then, by way of example, the channel width of the second switching element 210 is greater than the channel width of the first switching element 205 . [0040] FIG. 5 illustrates a fourth embodiment of a switching unit in a voltage supply. The same reference symbols or numerals are used for similar elements of the various embodiments. In the illustrated embodiment, a switching unit 501 has a control signal input 202 suitable for receiving a control signal. In one embodiment, the control input is the same as in FIG. 2 , FIG. 3 or FIG. 4 . In the illustrated embodiment, the control signal is provided for example by a control unit as illustrated in FIG. 1 . The control input 202 is coupled to an input of a first delay element 203 . An output of the first delay element 203 is coupled to an input of a second delay element 204 and the input of a seventh delay element 502 . The output of the second delay element 204 is coupled to a first switching element 205 . An output of the seventh delay element 502 is coupled to an input of an eight delay element 503 . An output of the eighth delay element 503 is coupled to an input of a ninth delay element 504 . The output of the eighth delay element 503 is additionally coupled to a seventh switching element 505 . The output of the ninth delay element 504 is coupled to an eighth switching element 506 . The output of the ninth delay element 504 is coupled to the input of a tenth delay element 507 and the input of an eleventh delay element 508 . The output of the eleventh delay element 508 is coupled to an input of a twelfth delay element 511 and also to further delay elements. The output of the tenth delay element 507 is coupled to a ninth switching element 509 . The output of the eleventh delay element 508 is coupled to a tenth switching element 510 . The output of the twelfth delay element 511 is coupled to an eleventh switching element 512 . Each of the outputs of the second delay element 204 , of the eighth delay element 503 , of the ninth delay element 504 , of the tenth delay element 507 , of the eleventh delay element 508 and of the twelfth delay element 511 may in be the starting point for a further “daisy chain”. [0041] In the event of a switch-on operation of the switching unit according to FIG. 5 , the first switching element 205 is closed in order to pre-charge the voltage domain. The seventh switching element 505 and the eighth switching element 506 are subsequently closed progressively. The ninth switching element 509 and simultaneously the tenth switching element 510 are subsequently closed in parallel. Afterwards, the eleventh switching element 512 and possibly a series of further switching elements over the voltage domain are closed. This enables a single switching element, namely the first switching element 205 , to be closed in the event of a switch-on operation. The seventh switching element 505 is subsequently closed, the embodiment of which switching element may be such that it has more current, that is to say a higher saturation current than the first switching element 205 . The eighth switching element 506 , which is subsequently closed, is also able to drive a higher current than the first switching element 505 . In one embodiment it is designed in the same way as the seventh switching element 505 . The next two switching elements are subsequently closed simultaneously, so that in total a higher current than previously can be driven. In the concluding part, a plurality of switching elements are closed in parallel, so that the charging operation overall proceeds more rapidly than if the switching elements are closed progressively. It is simultaneously ensured that precisely during charging, the current required for charging of the voltage domain is limited by the saturation currents of the switching elements. [0042] FIG. 6 illustrates a fifth embodiment of a switching unit in a voltage supply. The same reference symbols or numerals are used for similar elements of the various embodiments. In the illustrated embodiment, a switching unit has a control signal input 202 that is suitable for receiving a control signal, in various embodiments, such as is illustrated in FIG. 2 , FIG. 3 , FIG. 4 or FIG. 5 . The control signal is provided for example by means of a control unit as provided in FIG. 1 . [0043] In the illustrated embodiment, the control input 202 is coupled to an input of a first delay element 203 . An output of the first delay element 203 is coupled to a first switching element 205 and to a second switching element 210 . Furthermore, the output of the first delay element 203 is coupled to an input of a third delay element 206 . An output of the third delay element 206 is coupled to an input of a fourth delay element 209 . An output of the fourth delay element 209 is coupled to a third switching element 211 and to a fourth switching element 213 . Furthermore, the output of the fourth delay element 209 is coupled to an input of a fifth delay element 212 . This circuitry chain can be correspondingly continued, so that further switching elements are provided, to which the control signal is fed via further delay elements. In this case, it proves to be advantageous for the delay elements to be embodied as inverter elements, as is the case in this exemplary embodiment. A very compact configuration of the circuitry chain is obtained as a result. [0044] In the event of a switch-on operation for the switching unit in accordance with FIG. 6 , first of all the first switching element 205 and the second switching element 210 are closed. The third switching element 211 and the fourth switching element 213 are subsequently closed. In this case, by way of example, the first switching element 205 and the second switching element 210 are designed in such a way that they drive a small current. By contrast, the third switching element 211 and the fourth switching element 213 may be set up in such a way that they drive a higher current. The switching elements are distributed over a voltage domain, for example, so that first of all a current for pre-charging the voltage domain is switched on, which current turns out to be smaller than the current required for the connection of the voltage domain. [0045] It is advantageous that the control signal is passed to the switching elements via delay elements the delay elements likewise being supplied by the supply voltage. If the supply voltage drops to an excessively great extent as a result of an excessively rapid switch-on operation, a sufficient signal is not provided at the outputs of the delay elements, so that the control signal is not forwarded. Additional switching elements in the switch chain (daisy chain) are not closed. In one embodiment, this ensures that the voltage domain is charged rapidly overall without a dip in the supply voltage on the voltage supply and without causing a malfunction of the entire integrated semiconductor circuit in which the voltage domain is situated. [0046] In one embodiment, the daisy chain is having a tree structure, i.e. having different branches. By way of example, each branch may be designed equally. The branches may as well include different structures as e.g. shown in the FIG. 6 . [0047] In one embodiment the switching elements may be distributed over the voltage domain, so that a local charging of circuit elements takes place prior to a comprehensive connection of the supply voltage [0048] In one embodiment, the switching elements are arranged in a manner distributed uniformly over regions of the integrated semiconductor circuit in which is located at least one voltage domain whose voltage supply is to be switched. It is thereby possible, in the event of a connection operation, to effect rapid and uniform charging of the circuit elements in the voltage domain. [0049] In one embodiment the switching unit is located within the voltage domain. Supply lines between the switching unit and the voltage domain can thereby be made short. Unnecessary interference effects due to inductances and capacitances in the supply lines can be prevented in this way. [0050] In one embodiment, the first individual switching element, the second individual switching element and the third individual switching element are arranged in a manner distributed uniformly over regions of the integrated semiconductor circuit in which is located at least one voltage domain whose voltage supply is to be switched. It is thereby possible, in the event of a connection operation, to effect rapid and uniform charging of the circuit elements in the voltage domain. [0051] The embodiments shown may be combined as desired and/or according to the conditions of a voltage domain. In particular, different branches of the daisy chain may be provided.
One embodiment of the invention provides a circuit. The circuit includes a switching unit configured to connect or disconnect a voltage domain to a supply voltage input. The switching unit includes a first switch, a second switch and a third switch. The circuit includes a control signal input configured to receive a switch control signal. The circuit includes a signal distribution unit that is configured to output the switch control signal to the first switch delayed by a first time interval and to output the switch control signal to the second switch and to the third switch delayed by a second time interval.
8
BACKGROUND OF THE INVENTION The present invention is directed generally to an improved automatic vehicle distance control system and method. According to the article titled “Intelligent Tempomats Maintain Distance,” published in VDI-Nachrichten, 3 Sep. 1999, 35, page 20, distance control Tempomats (cruise-control systems) and automatic lane recognition are typical assist systems that will soon be available in trucks and buses. If, in a vehicle equipped with such automatic distance control capabilities, the distance from a vehicle driving in front becomes shorter than a preset safe distance, various braking devices are automatically actuated. For example, the retarder may be actuated, or the service brake may be used (which acts on all vehicle wheels). Vehicles having service brakes that can be automatically actuated are usually equipped with electronically controlled brake systems (EBS). For vehicles equipped with conventional brake systems, including anti-lock brake systems (ABS), and anti-slip regulation systems (ASR), however, the brakes cannot be actuated directly by an external signal or by an action not initiated by the driver. Such brake systems must be modified for this purpose, which can involve adding components, including additional solenoid valves, with associated undesired increases in vehicle complexity. Accordingly, it is desired to provide a vehicle equipped with a conventional ABS/ASR and automatic distance control with the capability of at least partial automatic actuation of the service brake in operation of the automatic distance control function, without undue complexity. SUMMARY OF THE INVENTION Generally speaking, in accordance with the present invention, for a vehicle equipped with a conventional ABS/ASR and automatic distance control, an improved system and method are provided to effect at least partial automatic actuation of the service brake in operation of the automatic distance control function, without undue complexity. The distance between the vehicle and a second vehicle driving in front of the vehicle and/or the approach speed of the vehicle with respect to the second vehicle is/are determined using the vehicle automatic distance control system which includes one or more distance sensors. If the distance between the vehicle and the second vehicle is less than a preselected safe distance, or if the approach speed of the vehicle with respect to the second vehicle has reached a speed that is critical for the distance from the second vehicle, the ASR function is actuated by the electronic control unit (ECU) of the ABS/ASR to brake the drive axle(s) of the vehicle. Brake actuation in connection with automatic distance control according to the present invention requires only software/program enhancement of the ECU. Additional hardware (such as additional solenoid valves) is not necessary. In one embodiment, the ECU is adapted to recognize if the vehicle brake pedal has been depressed, and, if so, automatic braking via the ASR is commensurately adjusted. In another embodiment, the ECU is adapted to effect variable pressure control of the brake cylinders of the drive axle(s) as a function of the distance between the vehicle and the second vehicle and/or the approach speed of the vehicle by appropriate actuation of ABS valves. In yet another embodiment, a trailer coupled to the vehicle can also be automatically braked by the vehicle automatic distance control system. An additional solenoid valve is provided which is actuatable by the ECU. If the distance between the first vehicle of the vehicle train and a vehicle driving in front is less than the preselected safe distance or if the approach speed of the vehicle train with respect to the vehicle driving in front has reached a speed that is critical for the distance from the vehicle in front, the ECU opens the additional solenoid valve together with the ASR valves to feed brake pressure to the trailer via a coupling head attached to the trailer. Accordingly, it is an object of the present invention to provide a commercial vehicle equipped with ABS/ASR with an improved automatic distance control system and method whereby at least partial automatic actuation of the vehicle service brake in operation of the automatic distance control function can be effected. It is also an object of the present invention to provide an improved automatic distance control system and method for a vehicle equipped with ABS/ASR that utilizes the ASR function to effect operation of the automatic distance control function. It is another object of the present invention to provide an improved automatic distance control system and method for a vehicle equipped with ABS/ASR that is not undesirably complicated. It is yet another object of the present invention to provide an improved automatic distance control system and method for a vehicle train equipped with ABS/ASR. Still other objects and advantages of the present invention will in part be obvious and will in part be apparent from the specification. The present invention accordingly comprises the various steps and the relation of one or more of such steps with respect to each of the others, and embodies features of construction, combinations of elements, and arrangement of parts which are adapted to effect such steps, all as exemplified in the following detailed disclosure, and the scope of the invention will be indicted in the claims. BRIEF DESCRIPTION OF THE DRAWINGS For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawing in which: FIG. 1 is a schematic diagram showing the pneumatic and electrical parts of a brake system for a conventional commercial vehicle having two drive axles or rear axles (HA 1 , HA 2 ) and a steering axle or front axle (VA); and FIG. 2 is a flow chart depicting the process flow for effecting vehicle automatic distance control according to one embodiment of the system and method of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to FIG. 1 , there is shown in simplified schematic form the brake system of a conventional commercial vehicle, generally indicated as 22 , having three axles VA, HA 1 and HA 2 . The wheels of the front axle VA are equipped with wheel-speed sensors 10 , 12 , and the wheels of the second rear axle HA 2 are equipped with wheel-speed sensors 11 , 13 . The output signals of the wheel-speed sensors 10 , 11 , 12 and 13 are delivered to an ABS/ASR ECU 9 . The front axle VA is braked by means of compressed air from a supply tank 16 . This air is released via a two-piece brake valve 21 , ABS valves 3 and brake cylinders 2 to brake the front vehicle wheels when the vehicle driver depresses a brake pedal 1 . While the brake system of the vehicle 22 depicted in FIG. 1 is of the pneumatic type, it should be understood that the present invention has application in vehicle brake systems which operate according to other principles. Also, because the brake system of the vehicle 22 depicted in FIG. 1 has generally symmetrical construction, for simplicity, only the valves and components of the right side of the vehicle are labeled with reference numbers. Service braking of the two rear axles HA 1 , HA 2 takes place from a second compressed air supply tank 17 . In this case, the compressed air is passed through the two-piece brake valve 21 to be delivered via a relay valve 7 and two ABS valves 6 to brake cylinders 4 , 5 of the two rear axles HA 1 , HA 2 . A second port (right) of the supply tank 17 is also in communication with the brake cylinders 4 , 5 via an ASR valve 8 , the relay valve 7 and the two ABS valves 6 . Instead of a common ASR valve 8 , it is also possible to provide two ASR valves, i.e., one for each side of the vehicle. The right port of the supply tank 17 is used for implementation of the ASR function. In cooperation with the ABS valves 6 connected on the output side, the ASR valve 8 is used, in known manner, for unilateral braking of any drive wheel that spins as it starts to move. For this purpose, it is actuated in ASR operation by the ECU 9 so as to cooperate with the associated right or left ABS valve 6 as soon as the ECU 9 detects, via the wheel-speed sensors 11 , 13 of the drive axle, that the drive wheels are spinning. Simultaneous actuation of the appropriate ABS valve ensures that the full supply pressure is not introduced. Indicator lights 14 , 15 are provided for monitoring the ABS and ASR functions. Referring now to FIG. 2 . a distance sensor 20 for sampling the distance to a vehicle driving in front of the vehicle 22 is also connected to the ECU 9 . The connection can be made directly or via a data bus installed in the vehicle 22 . The sensor 20 can be of any suitable conventional type which operates on known measurement principles, such as, for example, a radar, infrared or ultrasonic sensor. When the ECU 9 determines from data transmitted by the distance sensor 20 [step 1 ] that the distance to a vehicle driving in front of the minimum value [decision 2 A] or that the speed of approach to the vehicle in front is too high [decision 2 B] , it simultaneously actuates the ASR valve 8 as well as the two ABS valves 6 connected on the output side thereof, and thus delivers brake pressure to the brake cylinders 4 , 5 of the two rear axles HA 1 , HA 2 [step 3 ]. The vehicle 22 is commensurately braked until an appropriate distance to the vehicle in front is reestablished [see step 6 ]. The ECU 9 of the vehicle 22 preferably evaluates a combination of the distance to the vehicle in front and an approach speed that is critical for the current distance. It should be appreciated that brake actuation in connection with automatic distance control according to the present invention requires only software/program enhancement of the ECU 9 . Additional hardware (such as additional solenoid valves) is not necessary. If, in closing the distance between vehicle 22 and another vehicle driving in front, the driver of vehicle 22 has already depressed the brake pedal [decision 4 ], this is preferably recognized or sensed by the ECU 9 , and the automatic braking via the ASR valve 8 and the ABS valves 6 is commensurately reduced [step 5 ]. For this purpose, the ABS valves 6 and/or the ASR valve 8 can be actuated or closed as appropriate. If the vehicle 22 includes a trailer vehicle coupled thereto, the trailer can also be automatically braked advantageously by the automatic distance control system. For this purpose, there is provided, according to the present invention, an additional solenoid valve 18 which can be actuated by the ECU 9 . The additional solenoid valve 18 is pneumatically connected to the supply tank 17 . If the driving distance between the vehicle 22 and a vehicle driving in front becomes shorter than the preset minimum safe distance, the ECU 9 actuates or opens the solenoid valve 18 together with the ASR valves 8 . Also, brake pressure is fed via a coupling head 19 to the trailer vehicle. In one embodiment, it is further provided that, if braking is necessary because the vehicle 22 is getting too close to a vehicle in front, variable pressure control of the brake cylinders 4 , 5 of the drive axles is applied as a function of the distance and/or of the speed of approach to the vehicle in front. This is achieved by appropriately graduated actuation of the ABS valves 6 . Accordingly, smooth braking adapted to the situation can be achieved. Corresponding variable actuation of the brakes of an attached trailer vehicle is also achieved by graduated actuation of the additional solenoid valve 18 . Accordingly, the present invention enables the automatic distance control system in a vehicle equipped with conventional ABS/ASR to automatically brake the drive axle(s) through actuation of the ASR function when the distance to a vehicle driving in front becomes shorter than the preset safe distance. It should be appreciated that this represents a considerable advance over prior art arrangements in which distance control braking is effected by the retarder alone, since greater deceleration of the vehicle can be achieved when the drive axle(s) is(are) braked by means of the service brake. This is particularly true for loaded commercial vehicles in which the drive axle (rear axle) is carrying a heavier load. It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
A vehicle equipped with an anti-lock brake system (ABS) and with anti-slip regulation (ASR) and having the capability of automatically controlling the distance from a vehicle driving in front whereby various vehicle deceleration devices are actuated automatically if the distance becomes shorter than a preset minimum safe distance. For deceleration of the vehicle if the distance from a vehicle driving in front becomes shorter than the preset minimum safe distance, the ASR function used for braking the drive axles of the vehicle is actuated.
1
BACKGROUND OF THE INVENTION The present invention relates, in general, to a sunroof structure and more particularly, to a pop-out type sunroof structure. The sunroof structure of the present invention is readily adaptable for use in existing vehicles not now equipped with sunroofs and is very easy to operate. There are many sunroof structures that now exist and are used in a variety of different types of vehicles. For example, see my copending application Ser. No. 506,736 filed Sept. 16, 1974. Some of these structures, however, are rather complex, may be quite different to install in an existing vehicle, and do not easily provide for partial opening of the sunroof structure. Accordingly, it is an object of the present invention to provide an improved sunroof structure. A further object of the present invention is to provide a sunroof structure wherein the sunroof effeciently seals against the vehicle roof when in a closed position and can essentially be locked in this closed position. Another object of the present invention is to provide a sunroof structure that may be easily partially opened without having to completely remove the sunroof from engagement about its opening. In accordance with the preceding object it is still a further object of this invention to provide a sunroof that tilts so as to provide a partial opening thereof. Still a further object of the present invention is to provide a sunroof structure wherein the sunroof is preferably constructed of a plexiglass or acrylic material and has a sealing gasket attached about the periphery thereof. Still another object of the present invention is to provide a sunroof structure that is relatively simple in design, that is light in weight, that can be manufactured relatively inexpensively, and that can be easily installed in an existing vehicle. SUMMARY OF THE INVENTION To accomplish the foregoing and other objects of this invention, there is provided a sunroof structure for use in a vehicle having a roof opening beneath which the majority of the structure is disposed. The structure comprises a frame secured to the vehicle roof and extending about the roof opening, and a sunroof dimensioned to cover the roof opening. A gasket is disposed between the periphery of the sunroof and the edge defining the opening and this gasket is preferably secured to the periphery of the sunroof itself. A plurality of fasteners connect the frame to the sunroof and they may be uncoupled when the sunroof is to be removed from engagement with the frame. The sunroof may also be partially opened in which case some of the fasteners are holding at least an edge of the sunroof closed or in engagement with an edge of the frame. There is additionally provided a supporting arm which supports the opposite edge of the sunroof elevated above the vehicle roof so that the sunroof is in a partially opened position. BRIEF DESCRIPTION OF THE DRAWINGS Numerous other objects, features and advantages of the invention should now become apparent upon a reading of the following detailed description taken in conjunction with the accompanying drawings, in which: FIG. 1 is a perspective view of a vehicle showing the position of the sunroof structure; FIG. 2 is a cross sectional view taken along line 2--2 of FIG. 1, showing the sunroof structure in more detail; FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 2 showing further details of the sunroof structure; FIG. 4 is a plan view partially cut-a-way of the sunroof structure shown in FIG. 1; FIG. 5 is a somewhat enlarged fragmentary cross sectional view which is taken along line 5--5 of FIG. 3; and FIG. 6 is a fragmentary cross sectional view showing an alternate gasket sealing arrangement. DETAILED DESCRIPTION FIG. 1 shows the vehicle 10 having a roof 12 which is provided with an opening for receiving the sunroof structure 14 of the present invention. The sunroof structure 14 may be incorporated into a vehicle at the time that it is manufactured or is easily incorporated into a used vehicle. FIG. 2 shows more detail of the sunroof structure 14, the majority of which is disposed below the vehicle roof 12. The sunroof structure generally comprises a frame 16 and a plexiglass or acrylic sunroof 18. FIG. 3, which is a cross sectional view taken along line 3--3 of FIG. 2, shows further detail of the sunroof structure. FIG. 4 is a plan view of the sunroof structure with a section thereof partially cut-a-way. FIG. 5 is a detailed view taken along line 5--5 of FIG. 3 and showing the fastener and gasket seal. The frame 16, as most clearly shown in FIG. 5, has a stepped cross section including a top flange 20 which may be secured at predetermined distances along the frame by means of a bolt 22. The roof 12 is turned back at 24 about an elongated plate 26 and the lip 20 of the frame is secured by means of the bolt 22 which passes into and may be threaded into the plate 26. Another arrangement for fastening the frame 16 to the vehicle roof 12 is shown in FIG. 6 wherein a rivet 25 is used that extends through both the lip 20 and the roof 12. This arrangement is particularly suited for use with a vinyl cover 27 which covers the head of the rivet 25 and extends downwardly at its end. Although FIG. 5 shows a cross sectional view only at one point in the structure, it is understood that the plate 26 extends about the whole opening and is thus in the form of a rectangular plate with the roof cut and bent as shown in FIG. 5 about the plate 26. The lower end of frame 16 is turned up at 28 to form a gutter 30 having a bottom wall 31. The fastener 32 is secured by means of a rivet 34 to wall 31. A resilient strip 36 wedges between the wall 31, the support plate 38 for the fastener, and the inside roof head liner 40 which may be glued to the end 28 of the frame, as shown most clearly in FIG. 5. Although the sunroof is sealed by a gasket to the vehicle roof, there is a possibility that water may leak therebetween in which case this water would be collected in the gutter 30. In order to expell this water from the gutter, there is provided a plurality of vents 42 which are shown in FIG. 3 and in the cut-a-way section of FIG. 4. These vents can carry water from the gutter off to a place where it can be expelled from the vehicle. As shown in FIG. 4, there are preferably four fasteners 32 the details of which are shown in FIGS. 2, 3 and 5. Referring now, in particular, to FIG. 5, the fastener 32 generally comprises a support plate 38, a latch 44, and a curved spring 46. The support plate 38 has means defining a pivot point 45 about which the latch 44 can pivot. The spring 46 fastens at one end to pin 47 and has a hooked end 49 which engages with slot 50 in catch member 52. In FIG. 5 the fastener 32 is shown in its locked position with the latch 44 rotated counterclockwise about pivot 45 so that the raised portion 43 of the latch contacts the head liner 40. In that position the spring 46 in its tensioned position, pulling the catch member 52 downwardly and sealing the sunroof against the vehicle roof. The catch member 52 is secured to the flange 19 of the sunroof by means of a suitable fastening arrangement shown in FIG. 5 as including a screw 54 and a nut 56. This arrangement securely holds the catch member 52 against the bottom surface of the flange 19 of the sunroof. FIG. 5 also shows the sealing gasket 60 which peripherally extends, as shown in FIG. 4, about the entire sunroof. The gasket seal 60 fits about the end of the flange 19 and includes an outwardly extending end 62 and a hemispherical bottom 64. The gasket 60 and the frame 16 are constructed so that as the fasteners 32 are moved to their closed position, the lower end 64 of the gasket securely seals against the frame 16 as the outwardly extending end 62 seals against the roof 12 thereby providing a two-fold seal. FIG. 6 shows an alternate sealing arrangement. In FIG. 6 there is shown just a fragmentary end of the sunroof 18. The gasket 65 shown in FIG. 6 is an oval gasket or hemispherical gasket that is secured to the frame 16 rather than to the sunroof structure. In accordance with the present invention, it is desirable to partially open the sunroof to the position shown in dotted in FIG. 2. In this view, of course, the front of the vehicle is to the left and thus with the sunroof open in this manner, the wind forces on the vehicle as it is moving would not tend to lift the sunroof off and possibly damage the structure. In order to provide this type of operation, two of the fasteners 32 would be maintained in engagement with their respective catch members 52. In FIG. 2 the fasteners that are maintained in this position would be the fasteners on the left. The opposite two fasteners on the right, as viewed in FIG. 2, can be disengaged from their respective catch members by pulling down on flange 63 with the fingers thereby relieving the tension from the spring 46 and permitting the hooked end 49 to disengage from the hole 50 in the catch member. Once the two right hand fasteners, as viewed in FIG. 2, have been disengaged then the sunroof 18 can be tilted to the position shown in dotted in FIG. 2. In order to support the sunroof in that position, there is provided an arm 70 pivotally secured to the frame by bolt 72. The arm 70 when not in use is pivoted to the position shown in FIG. 3 so that it lies within the gutter 30. FIG. 3 also shows the end 74 of the arm 70 which may be a rubber member. The end 74 is adapted to engage with the button 76. This button 76 is secured to the flange 19 of the sunroof by a suitable means such as a bolt extending downwardly through the flange 19. As previously mentioned, FIG. 2 shows in phantom, the position of the arms 70 with its end 74 resting against the button 76 so as to hold the sunroof 18 in the position shown. When the sunroof is pivoted upwardly, the fasteners that are still connected tend to serve as a pivot point and as the sunroof is lifted, the tension in their springs 46 increases so that when the arm 70 is elevated to the proper position, there is a substantial downward force which tends to maintain the arm 70 in place. The end of the arm 74 and the button 76 could actually be mating suction cups that would provide for even more stable support for the sunroof 18. Having described one preferred embodiment of the present invention, it should now be apparent that one skilled in the art can make numerous modifications in the structures disclosed herein and that all such modifications and different embodiments thereof are contemplated as falling within the spirit and scope of the present invention. For example, the sunroof 18 can be fabricated of many different types of material. Also, there are numerous other types of securing means that can be used in place of those shown, such as in place of the bolt 22, shown in FIG. 5. Spot welding could even be used in place of the bolt 22.
The sunroof structure basically comprises a sunroof which is preferably constructed of a plexiglass or acrylic material and a preferably rectangular frame which is suitably supported from the vehicle roof structure and which defines an opening which the sunroof covers. The sunroof is of the pop-out type and a plurality of fasteners secure the sunroof in place to cover the opening. A peripheral gasket, which is preferably attached to the sunroof, provides a seal between the sunroof and the vehicle roof. The sunroof may be either completely removed or can be partially opened by pivoting the sunroof and supporting preferably its back edge by means of a pivotal support arm.
8
PRIORITY STATEMENT [0001] This application claims priority to and is a Continuation of application Ser. No. 10/641,346, entitled “One Card Poker with the Jokers Pokey Wheel” and filed on Aug. 14, 2003. BACKGROUND [0002] The present invention relates to a game apparatus, and more particularly to a game apparatus that utilizes playing card symbols with a rotating wheel. The use of a rotating wheel to play casino-type games (i.e., roulette) is known in the art, as illustrated in U.S. Pat. No. 1,670,692 to Rosar, U.S. Pat. No. 1,892,664 to Eyles, U.S. Pat. No. 3,941,389 to Guimond, and U.S. Pat. No. 5,188,363 to Marnell, II et al. However, none of these games combines the use of a rotating wheel with a stationary table to play poker using card indicia. [0003] U.S. Pat. No. 4,492,378 to Williams (“the '378 patent”) discloses a game apparatus that utilizes a rotatable wheel in combination with a playing table. Both the table and wheel include indicia from the standard fifty-two card playing deck. A single rotatable wheel has fifty-two segments representing the fifty-two cards of the standard playing card deck. The game combines the rotatable wheel with a horizontal play surface, which includes fifty-two spaces arranged in rows according to suit and columns according to denomination. Although the '378 patent, discloses a rotating wheel that can be used in combination with a horizontal playing surface, the arrangement of the card indicia on the wheel and the stationary wheel, and the method of playing the game is too complex to understand for even the skilled poker player. [0004] What is need in the art is a game apparatus, which utilizes playing card indicia, a rotating wheel, a horizontal game board, and elements of the card game Poker that is easy to understand and play. SUMMARY [0005] The disclosure is directed toward a game apparatus. The game apparatus comprises a rotatable wheel having a display surface divided into fifty-four concentric areas including indicia of fifty-two standard playing cards and indicia of two joker playing cards with stopping pegs disposed between each of the indicia of fifty-two standard playing cards and the indicia of two joker playing cards. The rotatable wheel is rotatably mountable to a stationary wheel having at least three tangs. The game apparatus also comprises a horizontal playing surface used in conjunction with the rotatable wheel. The horizontal playing surface has a main playing area divided into six columns of nine plots including indicia of fifty-two standard playing cards and indicia of two joker playing cards and a plurality of betting areas disposed on at least three borders of the main playing area. [0006] The disclosure also discloses that the indicia of the standard playing cards are represented by two, three, four, five, six, seven, eight, nine, ten, jack, queen, king and ace each in a suit of hearts, spades, diamonds, and clubs. [0007] The disclosure also discloses that the stationary wheel is mounted to a vertical support and the rotatable wheel is mounted on an axel attached to the stationary wheel. The disclosure also discloses that the stopping pegs physically interact with the at least three tangs to stop a rotation of the rotatable wheel. [0008] The disclosure also discloses that the indicia of fifty-two standard playing cards and the indicia of two joker playing cards are positioned on the rotatable wheel in an order including A♦; 6 ; 5♥; 7 ; K♦; Q ; J♥; 10 ; 9♦; 8 ; 7♥; 6 ; 5♦; 4 ; Q♦; 2 ; J♦; 9 ; small Joker; J ; 8♥; 5 ; A♥; 4 ; 7♦; K ; 8♦; A ; 10♦; Q ; 3♦; 9 ; 6♥; K ; 2♥; 8 ; 4♦; 10 ; 2♦; 3 ; Q♥; big Joker; K♥; 2 ; 4♥; 5 ; 10♥; 3 ; 6♦; A ; 3♥; 7 ; 9♥; and J . [0009] The disclosure also discloses that the game apparatus is configured to be a single apparatus and the game apparatus is configured to be an electronic apparatus. [0010] The disclosure is also directed to a method of playing a game apparatus. The method comprises placing a betting piece on a horizontal playing surface to make a bet. The horizontal playing surface comprises a main playing area divided into six columns of nine plots including fifty-two standard playing cards and two joker playing cards and a plurality of betting areas disposed on at least three borders of the main playing area. The method also comprises spinning a rotatable wheel about an axel disposed in a stationary wheel having at least three tangs. The rotatable wheel has a display surface divided into fifty-four concentric areas including indicia of fifty-two standard playing cards and two joker playing cards corresponding to the indicia of fifty-two standard playing cards and the indicia of the two joker playing cards of the game board. The rotatable wheel has stopping pegs disposed between each of the playing card indicia. The method comprises noting a position of each of the at least three tangs when rotational motion of the rotatable wheel is stopped by the at least three tangs and the stopping pegs. Lastly, the method comprises determining a winner of the bet. BRIEF DESCRIPTION OF THE FIGURES [0011] Referring now to the figures, wherein like elements are numbered alike: [0012] FIG. 1 is a perspective view of an exemplary embodiment of the rotatable wheel surrounded by the stationary wheel; [0013] FIG. 2 is a side view of the rotatable wheel and the stationary wheel of FIG. 1 illustrating the mounting arrangement; and [0014] FIG. 3 is a perspective view of an exemplary embodiment of the horizontal game surface. DETAILED DESCRIPTION [0015] Persons of ordinary skill in the art will realize that the following disclosure is illustrative only and not in any way limiting. Other embodiments of the invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. [0016] The present invention is a game apparatus that can be used to play poker. However, no physical playing cards are dealt to the players. The game apparatus utilizes a rotatable wheel and a horizontal playing surface (or game board) to play poker. The players make bets on the game board and the dealer spins the rotatable wheel. The rotatable wheel has three stopping positions (or tangs) that are utilized to determine the winner of the bets. The various games can be played against the dealer (as in regular poker) or as a roulette type game (a game of chance). Many variations of bets can be placed on the game board utilizing each individual stopping position or a combination of two or all of the stopping positions. [0017] Referring to FIGS. 1 and 2 , a rotatable wheel 10 is connected to a stationary back wheel 12 . As is seen in FIG. 2 , the rotatable wheel 10 and the stationary back wheel 12 are mounted on a vertical support 14 . Concentric with an axle 16 , the rotatable wheel 10 has low-friction bearings 18 , which enable it to spin freely on the axle 16 while the stationary back wheel 12 is rigidly secured to the vertical support 14 . A plurality of stopping pegs 20 in the form of rods, pins, and the like, project frontward from the rotatable wheel 10 and intersect a plurality of flexible stopping positions (or tangs) (three tangs 22 , 24 , 26 are illustrated in FIG. 1 ), which eventually stops rotation of the rotatable wheel 10 when rotational inertia of the rotatable wheel 10 is insufficient to bend the tangs 22 , 24 , 26 so as to clear the stopping pegs 20 . The three tangs 22 , 24 , 26 can be positioned as described in relation to a conventional clock to be at about 12 o'clock, about 9 o'clock and about 6 o'clock, respectively. Accordingly, when a person rotates the rotatable wheel 10 manually, the rotational position of the rotatable wheel 10 with respect to the stationary wheel 12 when the rotatable wheel 10 stops is determined only by chance. When utilizing this apparatus to play the game in which the angular position of the rotatable wheel 10 determines the outcome of the game, players rely on guesses which are registered on the game board 28 of FIG. 3 . [0018] Referring again to FIG. 1 , an exemplary rotatable wheel 10 is illustrated. The rotatable wheel 10 is divided by radii into fifty-four sectors 30 . Within each of the fifty-four sectors 30 are indicia of a standard playing deck of cards (i.e., fifty-two cards) 32 and two joker playing card indicia 34 for a total of fifty-four playing card indicia. The standard playing card indicia 32 include “two (2)”, “three (3)”, “four (4)”, “five (5)”, “six (6)”, “seven (7)”, “eight (8)”, “nine (9)”, “ten (10)”, “jack (J)”, “queen (Q)”, “king (K)” and “ace (A)” in the four suits of hearts (♥), spades ( ), diamonds (♦), and clubs ( ). The division of the rotatable wheel 10 into triangular areas 30 is only for the purposes of illustration, any configuration which includes fifty-four areas represented by the standard deck of playing cards and two joker playing cards is contemplated. [0019] The positioning of the standard playing card indicia 32 and the joker playing card indicia 34 on the rotatable wheel 10 is purposefully derived. The order of the standard playing card indicia 32 and the joker playing card indicia 34 on the rotatable wheel 10 allows for an equal number of losses and wins between the player and the dealer. The standard playing card indicia 32 and the joker playing card indicia 34 are disposed on the rotatable wheel 10 in the following order: A♦; 6 ; 5♥; 7 ; K♦; Q ; J♥; 10 ; 9♦; 8 ; 7♥; 6 ; 5♦; 4 ; Q♦; 2 ; J♦; 9 ; small Joker; J ; 8♥; 5 ; A♥; 4 ; 7♦; K ; 8♦; A ; 10♦; Q ; 3♦; 9 ; 6♥; K ; 2♥; 8 ; 4♦; 10 ; 2♦; 3 ; Q♥; big Joker; K♥; 2 ; 4♥; 5 ; 10♥; 3 ; 6♦; A ; 3♥; 7 ; 9♥; and J . [0020] Referring now to FIG. 3 , the horizontal game surface (or game board) 28 is illustrated. The game board 28 includes a main playing area 40 having indicia of a standard playing deck of cards (i.e., fifty-two cards) 36 and two joker playing card indicia 38 for a total of fifty-four cards disposed in six columns (or lines) of nine playing cards. The standard deck of cards indicia 36 include “two”, “three”, “four”, “five”, “six”, “seven”, “eight”, “nine”, “ten”, “jack”, “queen”, “king” and “ace” in the four suits of hearts, spades, diamonds, and clubs. The positioning of the standard playing card indicia 36 and the joker playing card indicia 38 on the game board 28 can correspond to the order presented above, or can be randomly arranged. [0021] Additionally, the game board 28 has other betting positions 42 disposed on either side of the main playing area 40 . These betting positions 42 can be grouped into three distinct areas card bets 44 , 44 a , 44 b , 44 c , 44 d , 44 e , 44 f , 44 g , column bets 46 , 46 a , 46 b , 46 c , 46 d , 46 e , 46 f, 46 g , 46 h , 46 i , 46 j , 46 k , and row and descriptive bets 48 , 48 a, 48 b, 48 c, 48 d, 48 e, 48 f, 48 g, 48 h, 48 i , 48 j , 48 k , 48 l . The betting positions 42 are described further herein and illustrated in part on FIG. 3 . [0022] The game apparatus illustrated in FIGS. 1, 2 , and 3 can be used to play several games, with the preferred game being Poker. The principle of the playing of the game apparatus is based on the worst hand of poker, in which the high card wins. In this game, the highest card is the joker playing card, followed by the ace, then the king, then the queen, etc. The playing of the game is derived from the nine hands of poker: straight flush, four of a kind, full house, flush, straight, three of a kind, two pair, one pair, and best card wins. [0023] The first tang 22 located at the clock position of twelve o'clock of the rotating wheel 10 represents the top card. The second tang 24 located at the clock position of nine o'clock of the rotating wheel 10 represents the dealer's card. The third tang 26 located at the clock position of six o'clock of the rotating wheel 10 represents the bottom card. Ideally, the dealer (not shown) will be positioned at the side 42 of the main playing area 40 near the rotatable wheel 10 with the players (not shown) surrounding the remaining areas of the game board 28 . [0024] In general, the playing of the game apparatus occurs as follows. A chip, bill or coin is placed on one of the playing cards 36 , 38 , or other areas as described above, on the game board 28 to make a bet and the rotatable wheel 10 is spun by the dealer or a player. When the rotatable wheel 10 stops, the dealer determines a winner based on the bets made and the positioning of the tangs (e.g., 22 , 24 , 26 ). [0025] One embodiment of playing the game apparatus is as follows. The playing card indicia 32 , 34 that is present at the second tang 24 is used to determine whether the player that bets on a playing card indicia 36 , 38 on the game board 28 wins bets to the top card (i.e., the playing card indicia 32 , 34 stopped by the first tang 22 ) or the bottom card (i.e., the playing card indicia 32 , 34 stopped by the third tang 26 ). For example, if the playing card indicia 32 , 34 of the second tang 24 is the big Joker, the playing card indicia 32 , 34 of the first tang 22 is the Ace of diamonds, and the playing card indicia 32 , 34 of the third tang 26 is the Ace of spades. The possible winners would be: [0026] 1.) a bet on the game board 28 betting position of high pair 44 e; [0027] 2.) a bet on the game board 28 betting position of any pair 44 g; [0028] 3.) a bet on the game board 28 playing card indicia 32 of the Ace of diamonds; [0029] 4.) a bet on the game board 28 betting position of odd top 48 e and odd bottom 48 i; [0030] 5.) a bet on the game board 28 betting position of red top 48 g; and [0031] 6.) a bet on the game board 28 betting position of diamonds. [0032] There following is a representation of the possible bets that can be placed using the game apparatus. Other betting configurations are contemplated. This list is descriptive of the possible bets and is not to be considered limiting. Examples of bets include: [0033] 1.) Board Bet—a bet is placed on one of the playing card indicia 36 , 38 of the game board 28 ; [0034] 2.) Split Bet—a bet is placed on the line between two playing card indicia 36 , 38 of the game board 28 ; [0035] 3.) Street Bet—a bet is placed to cover three playing card indicia 36 , 38 of the game board 28 ; [0036] 4.) Square Bet—a bet is placed to cover four playing card indicia 36 , 38 of the game board 28 ; [0037] 5.) Section Bet—a bet is placed to cover a section 48 a , 48 b , 48 c, 48 d of six of the playing card indicia 36 , 38 of the game board 28 ; [0038] 6.) Line Bet—a bet is placed to cover a column 46 f, 46 g , 46 h , 46 i , 46 j , 46 k of six of the playing card indicia 36 , 38 of the game board 28 ; [0039] 7.) Double Line Bet—a bet is placed to cover a two columns 46 a , 46 b , 46 c , 46 d , 46 e of six of the playing card indicia 36 , 38 of the game board 28 ; [0040] 8.) Long Line Bet—a bet is placed to cover a line of nine of the playing card indicia 36 , 38 of the game board 28 ; [0041] 9.) Double Long Line Bet—a bet is placed to cover a two lines of nine of the playing card indicia 36 , 38 of the game board 28 ; [0042] 10.) Tri-Bet—a bet is placed on any three lines of six of the playing card indicia 36 , 38 of the game board 28 ; [0043] 11.) Top Card Against the Dealer Bet—a bet is placed that the playing card indicia 36 , 38 in the top card position (i.e., at tang 22 ) is higher than the playing card indicia 36 , 38 in the dealer's card position (i.e., at tang 24 ); [0044] 12.) Bottom Card Against the Dealer Bet—a bet is placed that the playing card indicia 36 , 38 in the bottom card position (i.e., at tang 26 ) is higher than the playing card indicia 36 , 38 in the dealer's card position (i.e., at tang 24 ); [0045] 13.) Top Card Even Bet—a bet is placed that the playing card indicia 36 , 38 in the top card position (i.e., at tang 22 ) is an even numbered playing card indicia 36 , 38 (in the case the Joker appears, the bet stays or can be removed by the player); [0046] 14.) Bottom Card Even Bet—a bet is placed that the playing card indicia 36 , 38 in the bottom card position (i.e., at tang 26 ) is an even numbered playing card indicia 36 , 38 (in the case the Joker appears, the bet stays or can be removed by the player); [0047] 15.) Top Card Odd Bet—a bet is placed that the playing card indicia 36 , 38 in the top card position (i.e., at tang 22 ) is an odd numbered playing card indicia 36 , 38 (in the case the Joker appears, the bet stays or can be removed by the player); [0048] 16.) Bottom Card Odd Bet—a bet is placed that the playing card indicia 36 , 38 in the bottom card position (i.e., at tang 26 ) is an odd numbered playing card indicia 36 , 38 (in the case the Joker appears, the bet stays or can be removed by the player); [0049] 17.) Suit Bet—a bet is placed on one of the suit positions (i.e., hearts, spades, diamonds, clubs) of the game board 28 ; [0050] 18.) Three of a Kind Bet—a bet is placed that three of the same numbered playing card indicia 36 will be stopped by the tangs 22 , 24 , 26 (i.e., seven of hearts, seven of diamonds, and seven of spades); [0051] 19.) High Pair Bet—a bet is placed that a pair of high card 44 e playing card indicia 36 will be stopped by two of the tangs 22 , 26 ; [0052] 20.) Low Pair Bet—a bet is placed that a pair of low card 44 b playing card indicia 36 will be stopped by two of the tangs 22 , 26 ; [0053] 21.) Any Pair Bet—a bet is placed that any pair 44 g of the playing card indicia 36 will be stopped by the tangs 22 , 24 , 26 ; [0054] 22.) Specific Bet—a bet is placed on betting positions as follows 7-7-7, A-A, 2-2, or 7 - 7 ( 44 a , 44 b , 44 c , 44 d ) will be stopped by the tangs 22 , 24 , 26 ; [0055] 23.) Color Black Bet—a bet is placed that the playing card indicia 36 , 38 in the top card position (i.e., at tang 22 ) is black (the Big Joker is considered black) 46 h ; [0056] 24.) Color Black Bet—a bet is placed that the playing card indicia 36 , 38 in the bottom card position (i.e., at tang 26 ) is black (the Big Joker is considered black) 48 l; [0057] 25.) Color Red Bet—a bet is placed that the playing card indicia 36 , 38 in the top card position (i.e., at tang 22 ) is red (the Little Joker is considered red) 48 g ; and [0058] 26.) Color Red Bet—a bet is placed that the playing card indicia 36 , 38 in the bottom card position (i.e., at tang 26 ) is red (the Little Joker is considered red) 48 k. [0059] Although the present invention is described herein as a game apparatus that is physically two separate playing areas, it is contemplated that the two separate playing areas can be combined into a single stand-alone device. It is also contemplated that the game apparatus can be utilized as an electronic game apparatus having push buttons to place bets and activate the wheel. [0060] The present invention is a game apparatus that utilizes a rotatable wheel and a game board to play poker. The players make bets on the game board and the dealer spins the rotatable wheel. The advantage of this game apparatus is that one player can play against the dealer at the same time that a player can play the game of chance against the rotatable wheel. The game apparatus is easy to understand and allows lovers of roulette to expand their abilities to include elements of poker. [0061] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention.
A game apparatus is disclosed. The game apparatus comprises a rotatable wheel having a display surface divided into fifty-four concentric areas including indicia of fifty-two standard playing cards and indicia of two joker playing cards with stopping pegs disposed between each of the indicia of fifty-two standard playing cards and the indicia of two joker playing cards. The rotatable wheel is rotatably mountable to a stationary wheel having at least three tangs. The game apparatus also comprises a horizontal playing surface used in conjunction with the rotatable wheel. The horizontal playing surface has a main playing area divided into six columns of nine plots including indicia of fifty-two standard playing cards and indicia of two joker playing cards and a plurality of betting areas disposed on at least three borders of the main playing area.
0
CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation of and claims priority under 35 U.S.C. § 120 to U.S. application Ser. No. 10/660,571, filed Sep. 12, 2003, now U.S. Pat. No. 6,898,407 the entire contents of which are incorporated herein by reference. This application is also based upon and claims priority under 35 U.S.C. to Japanese Patent Application No. 2002-266629, filed Sep. 12, 2002. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a color image forming apparatus, and more particularly to a color image forming apparatus realized in a compact desktop size by reducing a total height while securing a sufficient length necessary for a sheet path between an image transfer point and an image fixing point. Also, the present invention relates to a method of making the above-mentioned color image forming apparatus. 2. Discussion of the Background In recent years, an electrophotographic image forming apparatus has been increasingly demanded in a full-color version, such as a color printer, a color copying machine, and so forth. In response, quite a large number of full-color image forming apparatuses have been introduced to the market. In comparison with a monochrome image forming apparatus, a full-color image forming apparatus inevitably has larger dimensions, due to its structure, and achieves a relatively lower performance in image forming, e.g., a lower image forming speed. However, there is also a great demand for the full-color image forming apparatus to have a compact size, such as the monochrome printer, capable of being placed on a desk and to be able to perform at a relatively high image forming speed. In the full-color image forming apparatus, there are two adoptable color recording methods; a single drum type and a tandem drum type. The single-drum-type image forming apparatus has a typical configuration in which a plurality of development units are arranged around a single photosensitive drum. The development units contain different color toners and sequentially transfer the color toners to the surface of the photosensitive drum so as to form a composite color image. The composite color image is then transferred onto a recording sheet. On the other hand, the tandem-drum-type image forming apparatus has a plurality of photosensitive drums arranged in line and forms single-color toner images with different color toners on the corresponding photosensitive drums. Then, the single-color toner images are sequentially transferred onto a recording sheet so as to form a composite color toner image. The single-drum type has advantages in size and cost, in comparison with the tandem-drum type, but also has difficulty in enhancing the image forming speed due to the need to repeat image forming, which is normally repeated four times. On the contrary, the tandem-type has disadvantages in size and cost, but has an advantage in the enhancement of the image forming speed. Under the aforementioned circumstances, increasing attention has been focused on full-color image forming apparatus based on the tandem drum type, to attain high speed image forming like the monochrome printer. There are two different types of tandem-drum image forming apparatuses, as shown in FIGS. 1 and 2 . In the tandem-drum image forming apparatus shown in FIG. 1 , images formed on four photosensitive drums 51 , arranged in line, are sequentially transferred by corresponding image transfer units 52 onto a recording sheet, which is conveyed from a sheet supply unit 60 to an image fixing unit 61 by a sheet conveying belt 53 . This method is referred to as a direct image transfer method. In the tandem-drum image forming apparatus shown in FIG. 2 , in which components equivalent to those shown in FIG. 1 are given the same numeral references, images formed on the four photosensitive drums 51 , arranged in line, are sequentially transferred by corresponding primary image transfer units 52 to form a composite color image onto an intermediate transfer belt 54 . Then, the composite color image carried by the intermediate transfer belt 54 is transferred by a secondary image transfer unit 55 onto a recording sheet, which is conveyed from a sheet supply unit 60 to an image fixing unit 61 by a sheet conveying belt 53 . This method is referred to as an indirect image transfer method. In the tandem-drum-type image forming apparatus of FIG. 1 , which adopts the direct image transfer method, the sheet supply unit 60 and the image fixing unit 61 need to be arranged upstream and downstream, respectively, in a sheet conveying direction relative to the four-tandem-drum mechanism. Therefore, the apparatus using the direct image transfer method is inevitably upsized in the sheet conveying direction, which is a drawback of this type of apparatus. On the contrary, in the image forming apparatus of FIG. 2 , which adopts the indirect image transfer method, the secondary image transfer unit 55 can be positioned rather freely and, thus, a transfer path for the recording sheet can be shortened. Therefore, it is possible to reduce the size of the apparatus by using the indirect image transfer method. From the above explanation, a full-color image forming apparatus preferably has the tandem-drum-type from the viewpoint of high speed, and preferably adopts the indirect image transfer method from the viewpoint of downsizing. In the full-color image forming apparatus using the tandem-drum mechanism and the indirect image transfer method, a vertically-extended sheet transfer mechanism can be employed to minimize a sheet travel distance, along the sheet transfer path, from a sheet inlet of the sheet supply unit to the fixing unit. In this instance, the speed of image forming can be enhanced by reducing the amount of the sheet travel distance. Further, with this structure, the occurrence of a deficiency such as a sheet jamming may be suppressed. In such an apparatus using the vertically-extended sheet transfer mechanism, the second image transfer unit 55 is necessarily positioned next to one end of the intermediate transfer belt 54 (e.g., next to the right of the intermediate transfer belt 54 ), as shown in FIG. 3 . In this instance, if four image forming mechanisms 50 including the photosensitive drums 51 a are arranged in line on and along the upper running surface of the intermediate transfer belt 54 , an overlaid composite color image is created on the intermediate transfer belt 54 when a black color toner (Bk) is transferred onto the intermediate transfer belt 54 . The black color toner (Bk) is the last toner transferred in the image forming sequence and, therefore, the overlaid composite color image is brought close to the secondary image transfer unit 55 only after a half turn of the intermediate transfer belt 54 . This makes the first copy time relatively long. The first copy time is one of the speed indicators for image forming apparatuses, and indicates a speed for copying a first page. To improve the first copy time in the above-mentioned image forming apparatus, the four image forming mechanisms 50 are arranged on and along the lower running surface of the intermediate transfer belt 54 , instead of on and along the upper running surface thereof, as shown in FIG. 4 . FIG. 5 is a top view of the image forming apparatus of FIG. 4 . With this structure, the length of the sheet transfer path is minimized and the first copy time is improved, since the overlaid composite color can be brought close to the secondary image transfer unit 54 immediately after the transfer of the black color toner (Bk) is completed. As described above, based on the presently available techniques, a desk-top and high speed full-color image forming apparatus may be realized, most preferably by using the tandem-drum image forming mechanism, the indirect image transfer method, and the vertical sheet conveying path. It should be noted that in an electrophotographic image forming apparatus, the sheet conveying path between the image transfer point and the fixing point needs to have a distance to a certain extent determined by the size of the sheets applied or the like. The reason for this is explained with reference to FIG. 6 . In FIG. 6 , the secondary image transfer unit 55 has a line speed b and the fixing unit 61 has a line speed a. Ideally, the line speeds a and b would be equal to each other. However, making the line speeds a and b equal to each other is not practical, in general, due to manufacturing tolerances, even if they are designed to be equal to each other. When the line speed b of the image transfer is slower than the line speed a of the image fixing, the leading edge of the recording sheet may reach the fixing unit 61 before the rear part of the recording sheet passes by the image transfer unit 55 , depending upon the size of the recording sheet. In this case, the recording sheet under the image transfer process is forcibly pulled forward by the fixing unit 61 and, as a result, image displacement is caused. To avoid this, the line speed b is generally designed to be faster than the line speed a. However, when the line speed b is faster than the line speed a, the recording sheet may have slack or a bend that causes the toner image on the recording sheet to contact a part of the machine. As a result, the toner image on the recording sheet is disturbed. Therefore, the sheet passage between the image transfer unit 55 and the fixing unit 61 should have a length h that can accommodate slack or a bend of the recording sheet. Based on this structure, a vertical distance (i.e., a height h sin β; see FIG. 7 ) from the image transfer point to the fixing point is determined to avoid the above-mentioned image displacement problem by satisfying relationships a≦b, (b−a)xc/b=1, and Bmax≦BBmax. In these relationships, a is the line speed of the fixing rollers, b is the line speed of the image transfer rollers, c is the length of the recording sheet in the sub-scanning direction, Bmax is a maximum amount of a slack or a bend of the recording sheet caused between the image transfer point to the fixing point, and Bbmax is a maximum permissible amount of a slack or a bend of the recording sheet caused between the image transfer point to the fixing point. In a full color image forming apparatus employing tandem-drum-type image forming and indirect image transfer, as well as a vertical sheet conveying path, it is considerably difficult to decrease the total height of such apparatus while securing a reasonably sufficient distance between the image transfer point and the fixing point. If the full color image forming apparatus is a desk-top machine, it is generally required to have a smaller profile in every dimension. However, the most critical dimension is the height, since it directly affects the ability of the user to access the recording sheets in the ejection tray, to remove the jammed sheets, to exchange the toner cartridge, and so forth. The difficulty lies in the relationship between securing the certain distance between the image transfer point and the fixing point, and in reducing the machine height, which are contradictory objectives. SUMMARY OF THE INVENTION In view of the foregoing, it is an object of the present invention to provide a novel color image forming apparatus which realizes a compact desktop profile while securing a sufficient length between a secondary image-transfer point and a fixing point. Another object of the present invention is to provide a novel method of making a color image forming apparatus which realizes a compact desktop profile while securing a sufficient length between a secondary image-transfer point and a fixing point. To achieve the above-mentioned objects and other objects, in one example, the present invention provides a novel color image forming apparatus including an image generating mechanism and a sheet supply mechanism. The image generating mechanism includes an image forming mechanism, an optical writing mechanism, an intermediate image-transfer member, a fixing mechanism, a sheet ejecting mechanism, a toner container, and an electric circuit. The image forming mechanism forms an image and includes a plurality of image creating mechanisms, each of which forms an image and includes a photosensitive member. The optical writing mechanism optically writes an image on the photosensitive member of each of the plurality of image creating mechanisms. The intermediate image-transfer member has an image transfer bed, moving in a predetermined direction in a lower part of the intermediate image-transfer member, to receive a plurality of the images from the respective photosensitive members, such that the plurality of the images are sequentially overlaid to form a multi-overlaid image. The fixing mechanism fixes the multi-overlaid image on a recording sheet. The sheet ejecting mechanism ejects the recording sheet having the fixed multi-overlaid image thereon. The container replenishes toner to the image forming mechanism. The electric circuit includes a plurality of circuit blocks and supplies power and necessary signals to the apparatus. The sheet supply mechanism supplies recording sheets through a sheet inlet thereof to the image generating mechanism. In this apparatus, the intermediate image-transfer member is arranged with a predetermined angle relative to a horizontal line, such that a rear side of the intermediate image-transfer member away from the recording sheet is lifted and a front side of the intermediate image-transfer member closer to the recording sheet is lowered. Further, the plurality of image creating mechanisms are aligned in parallel and are arranged along and parallel to the image transfer bed of the intermediate image-transfer member, such that one of the plurality of image creating mechanisms firstly forming an image faces the rear side of the image transfer bed and another one of the plurality of image creating mechanisms lastly forming an image faces the front side of the image transfer bed. The present invention also provides a novel method of making a color image forming apparatus. BRIEF DESCRIPTION OF THE DRAWINGS A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description, when considered in connection with the accompanying drawings, wherein: FIG. 1 is a schematic diagram of a background color image forming apparatus with a direct-transfer method and a tandem image forming mechanisms; FIG. 2 is a schematic diagram of a background color image forming apparatus with an indirect-transfer method and the tandem image forming mechanisms; FIG. 3 is a schematic diagram showing another view of the background color image forming apparatus of FIG. 2 ; FIG. 4 is a schematic diagram of an improved version of the background color image forming apparatus of FIG. 2 ; FIG. 5 is a top view of the improved version of the background color image forming apparatus of FIG. 2 ; FIG. 6 is an illustration for explaining a problem occurring in connection with a sheet conveyance between an image transfer point to a fixing point; FIG. 7 is a schematic diagram of a color laser printer as one example of a color image forming apparatus according to a preferred embodiment of the present invention; FIG. 8 is an illustration for explaining a space having a cross section of triangular shape formed underneath an optical writing unit tilted together with an intermediate transfer belt and an image forming mechanism; FIG. 9 is a top view of the color laser printer of FIG. 7 ; FIGS. 10-13 are schematic diagrams of the color laser printer of FIG. 7 indicating definitions of points, lengths, angles, and mathematical formulas associated with the layout of the color laser printer of FIG. 7 ; FIG. 14 is an illustration for showing an openable upper cover of the color laser printer of FIG. 7 ; FIGS. 15 and 16 are schematic diagrams of a modified version of the color laser printer of FIG. 7 in which a toner cartridge 36 d has a greater radius than others; and FIG. 17 is a schematic diagram of another modified version of the color laser printer of FIG. 7 in which toner cartridges 36 a - 36 d have a prism shape. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS In describing preferred embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, particularly to FIG. 7 , a description is made for a color laser printer 100 as one example of a color image forming apparatus according to a preferred embodiment of the present invention. As shown in FIG. 7 , the color laser printer 100 is provided with a main body 1 and a sheet supply mechanism 2 mounted under the main body 1 . The main body 1 includes an image forming station 3 mounted over the sheet supply mechanism 2 . In the image forming station 3 , an intermediate transfer belt 7 including an endless belt and serving as an image carrying member is extended under pressure between a plurality of rollers 4 , 5 , and 6 . A portion of the intermediate transfer belt 7 between the rollers 4 and 5 corresponds a lower side of the intermediate transfer belt 7 and forms a moving image forming bed. An image forming unit 8 which includes four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk are mounted to face this moving image forming bed. Each of the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk includes a photosensitive drum 10 serving as a latent image carrying member brought in contact with the intermediate transfer belt 7 . Each image forming mechanism further includes a charging unit 11 , a development unit 12 , a cleaning unit 13 , which are arranged around the photosensitive drum 10 , and a transfer unit 14 . The transfer unit 14 serves as a primary transfer mechanism and is arranged inside the intermediate transfer belt 7 at a position where the photosensitive drum 10 contacts the intermediate transfer belt 7 . In this example, the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk have an identical structure, but colors of development agents contained in their development units 12 are separated into yellow, cyan, magenta, and black colors per the development unit 12 . Under the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk, an optical writing unit 15 is arranged. The optical writing unit 15 generates a light-modulated laser beam to irradiate the surface of the photosensitive drum 10 between the charging unit 11 and the development unit 12 . In this example, the optical writing unit 15 is a single unit shared by the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk so as to gain a cost benefit. As an alternative, it is also possible to provide four independent optical writing units for the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk. When an image forming operation is started, the photosensitive drums 10 of the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk are clockwise rotated by a driving mechanism (not shown) and the surfaces of the photosensitive drums 10 are charged evenly at a predetermined polarity. The charged surfaces are irradiated by the laser beams emitted from the optical writing unit 15 , so that electrostatic latent images are formed on the surfaces of the photosensitive drums 10 . In this process, the laser beams respectively transfer image information onto the surfaces of the photosensitive drums 10 for the above-mentioned electrostatic latent images. The image information is of four kinds of single color image information obtained by separating a desired full-color image into information of yellow, cyan, magenta, and black colors. When each of the thus-formed electrostatic latent images passes by the corresponding development unit 12 , the latent image is developed by the development agent contained in the development unit 12 into a visual corresponding toner image. One of the rollers 4 , 5 , and 6 of the intermediate transfer belt 7 is counterclockwise rotated by a driving mechanism (not shown) and the intermediate transfer belt 7 is moved in a direction indicated by an arrow. The remaining rollers follow the rotation. The moving intermediate transfer belt 7 receives thereon a yellow toner image formed by the image forming mechanism 8 Y having the development unit 12 for the yellow color and transferred by the transfer unit 14 . Subsequently, a cyan toner image, formed by the image forming mechanism 8 C having the development unit 12 for the cyan color and transferred by the transfer unit 14 , is superimposed onto the yellow toner image. Likewise, magenta and black toner images formed by the image forming mechanisms 8 M and 8 Bk, respectively, having the development units 12 for the magenta and black colors, respectively, and transferred by the corresponding transfer units 14 , are sequentially superimposed onto the toner image made of the yellow and cyan colors. Consequently, a full color toner image made of the yellow, cyan, magenta, and black colors is formed on the surface of the moving intermediate transfer belt 7 . A secondary transfer unit 20 is arranged to face the roller 6 relative to the intermediate transfer belt 7 , and a belt cleaning unit 21 for cleaning the surface of the intermediate transfer belt 7 is arranged to face the roller 4 relative to the intermediate transfer belt 7 . The residual toner remaining on the surface of the photosensitive drum 10 after the toner image transfer process is removed by the cleaning unit 13 from the surface of the photosensitive drum 10 . Subsequently, the surface of the photosensitive drum 10 is discharged by a discharging mechanism (not shown), so that a surface potential of the photosensitive drum 10 is initialized as a preparation for the next image forming operation. During the above-described operations, a recording sheet made of paper or a plastic resin is supplied from the sheet supply mechanism 2 to the image forming station 3 through a sheet inlet 2 a of the sheet supply mechanism 2 . The recording sheet inserted into the image forming station 3 is conveyed to a secondary transfer point formed between the secondary transfer unit 20 and the roller 6 , via a pair of registration rollers 24 . At this time, the secondary transfer unit 20 is applied by a transfer voltage having a reverse polarity relative to the charge polarity of the toner image formed on surface of the intermediate transfer belt 7 , so that the full color toner image on the intermediate transfer belt 7 is transferred onto the recording sheet. The recording sheet receiving the full color image is further conveyed to a fixing unit 22 . The toner is then melted and fixed by heat and pressure to the recording sheet by the fixing unit 22 . Then, the recording sheet with the fixed toner image is ejected to an output tray 23 through a pair of ejection rollers 23 a . The surface of the intermediate transfer belt 7 is cleaned off by the belt cleaning unit 21 so that the residual toner remaining on the intermediate transfer belt 7 is removed therefrom after the secondary toner image transfer operation. The above-described operation is the one in which a full color image is formed on the recording sheet using the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk. As an alternative, it is also possible to form a single color image or two- or three-colored image selectively using the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk. The color laser printer 100 having, as shown in FIG. 7 , the above-described structure to provide the four development units for the respective colors, is capable of executing the image forming operation in a time period significantly shorter than a printer having a single development unit which contains the four color toners and uses them one by one. The color laser printer 100 of FIG. 7 has a further advantage of a first print faster than even the tandem-type image forming apparatus of FIG. 3 , in which the image forming mechanism is arranged above the moving intermediate transfer belt. It should be noted that in the color laser printer 100 , the moving image forming bed of the intermediate transfer belt 7 formed between the rollers 4 and 5 is tilted with a predetermined angle θ relative to the horizontal line, and the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk are arranged in parallel to the moving image forming bed. The slant of the moving image forming bed is made to the right in the drawing, that is, the image forming mechanism located at a more downstream position in the moving direction of the intermediate transfer belt 7 is at a lower horizontal level. The color laser printer 100 of FIG. 7 has a structure similar to that of the image forming apparatus of FIG. 4 , but has a reduced height. As a result, the path between the sheet supply unit 2 and the fixing unit 22 is shorter. However, even with such a shorter path between the sheet supply unit 2 and the fixing unit 22 , a requisite distance h between the secondary transfer unit 20 to the fixing unit 22 is securely obtained while the color laser printer 100 maintains a reduced height, by the arrangement of tilting the intermediate transfer belt 7 . If the moving image forming bed of the intermediate transfer belt 7 is horizontally arranged in a way as shown in FIG. 4 , the entire intermediate transfer belt 7 needs to be set at an even horizontal level. In comparison with this, the color laser printer 100 of FIG. 7 has the intermediate transfer belt 7 slanted to the right with the predetermined angle θ relative to the horizontal line and, accordingly, a relatively large space having an approximately-triangular cross section is made at the left bottom of the main body. This space is illustrated as a hatched space in FIG. 8 . When the length of the optical writing unit 15 is A, the hatched cross sectional triangle becomes an approximately-right-angled triangle having a height of A sin θ and a bottom of A cos θ. This triangular space is large enough to accommodate electrical components, and when the electrical components are arranged in the triangular space, the color laser printer 100 can be downsized both in height and length. As indicated in FIG. 7 , the color laser printer 100 has a height of 468 mm and a length of 570 mm. The above-mentioned electrical components of the color laser printer 100 include a high voltage power supply unit 30 , a control unit 31 , and an engine controller 33 . The high voltage power supply unit 30 supplies a high voltage power required by the above-described image forming processes. The control unit 31 controls the conversion of image signals sent from a host computer into internal control signals. The engine controller 32 controls the entire operations of the color laser printer 100 . Thus, in the color laser printer 100 , most of the electrical components are arranged underneath the optical writing unit 15 and, therefore, the downsizing of the color laser printer 100 is achieved. Amongst the electrical components, a power supply unit 33 is vertically arranged at the back of the main body. In the color laser printer 100 , four toner cartridges 36 a , 36 b , 36 c , and 36 d having a cylindrical shape contain the yellow (M), cyan (C), magenta (M), and black (Bk) color toners, respectively. The four toner cartridges 36 a , 36 b , 36 c , and 36 d are arranged in this order in parallel to each other, along a line having the angle θ relative to the horizontal line, that is, parallel to the moving image forming bed, as illustrated in FIG. 7 , to supply the Y, C, M, and Bk color toners to the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk, respectively. In this structure, the toner cartridge 36 a for the Y color toner is located at the highest position in the vertical direction. Likewise, the toner cartridge 36 b for the C color toner is located at the second highest position, the toner cartridge 36 c at the third highest position, and the toner cartridge 36 d at the lowest position in the vertical direction. The above-mentioned four toner cartridges 36 a - 36 d are accommodated inside the main body 1 under an upper cover 37 . FIG. 9 is a top plan view of the color laser printer 100 , indicating that the width of the color laser printer 100 is 420. In the color laser printer 100 , the layout of the image forming station 3 is expressed by using mathematical formulas with the following definitions of points, lengths, angles, and so on for the associated components, as illustrated in FIGS. 10-13 . In this discussion, X and Y represent horizontal and vertical directions, respectively, x and y represent variants in the directions X and Y, respectively, and O represents the origin of this X-Y coordination system, which is at the bottom and leftmost corner of the color laser printer 100 in the drawing. In addition, HL represents a horizontal line and CL represents a center line. Further, HS(x,y) represents a sheet ejection point at which the recording sheets having full-color images are ejected by the pair of ejection rollers 23 a . TT(x,y) represents a fixing point which is a center point of a fixing nip region formed in the fixing unit 22 . TS(x,y) represents a secondary image transfer point at which the secondary image transfer is performed by the secondary transfer unit 20 . RE(x,y) represents a registration point at which the registration is performed by the pair of the registration rollers 24 . BR(x,y) represents a sheet separation point at which the recording sheet, yet having no image thereon, is separated from other recording sheets remaining in the sheet supply mechanism 2 and is transferred into the image forming station 3 through the sheet inlet 2 a. T 1 (x,y) represents the highest point of the highest positioned toner cartridge 36 a . T 2 (x,y) represents the lowest point of the highest positioned toner cartridge 36 a . T 3 (x,y) represents the highest point of the lowest positioned toner cartridge 36 d . T 4 (x,y) represents the lowest point of the lowest positioned toner cartridge 36 d . T 5 (x,y) represents a point of the toner cartridges 36 a - 36 d having the shortest distance to the fixing point TT(x,y). Also, various angles of lines in relation to the horizontal line HL are defined as follows. As described above, the character θ represents the angle of the moving image forming bed formed by the intermediate transfer belt 7 relative to the horizontal line HL. A character φ represents an angle of a line between the secondary image transfer point TS(x,y) and a point of the intermediate transfer belt 7 at which a side edge line of a unit of the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk, extended in a direction perpendicular to the intermediate transfer belt 7 , intersects the intermediate transfer belt 7 . A character γ represents an angle of a line formed between the secondary transfer point TS(x,y) and the sheet separation point BR(x,y) relative to the horizontal line HL. A character β represents an angle of a line formed between the fixing point TT(x,y) and the secondary image transfer point TS(x,y). Various lengths are defined as follows. A term d 1 represents a distance between the moving image forming bed of the intermediate transfer belt 7 and a bottom side of the optical writing unit 15 , sandwiching the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk. A term d 2 represents a vertical distance in the direction Y between the sheet separation point BR(x,y) and a bottom corner edge of the optical writing unit 15 closer to the sheet supply mechanism 2 . A term d 3 represents a distance between the secondary image transfer point TS(x,y) and the point of the intermediate transfer belt 7 at which the side edge line of the unit of the four image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk, extended in the direction perpendicular to the intermediate transfer belt 7 , intersects the intermediate transfer belt 7 . A term D represents a vertical distance in the direction Y between the secondary image transfer point TS(x,y) and the sheet separation point BR(x,y). A term HI represents a distance between the point T 5 (x,y) and the fixing point TT(x,y), which is referred to as a toner fixation prevention distance. A term HIx represents a horizontal distance in the direction X between the point T 5 (x,y) and the fixing point TT(x,y), which is an element in the direction X of the toner fixation prevention distance. A term HIy represents a vertical distance in the direction Y between the point T 5 (x,y) and the fixing point TT(x,y), which is an element in the direction Y of the toner fixation prevention distance. A term h represents a distance between the fixing point TT(x,y) and the secondary image transfer point TS(x,y). A term N (see FIG. 12 ) represents a distance between the center points of the toner cartridge 36 a for the Y color toner and the toner cartridge 36 d for the Bk color toner. A term R 1 represents a radius of each of the four toner cartridges 36 a - 36 d . A term R 2 (see FIG. 16 ) represents a radius of the toner cartridge 36 d when the radius of the toner cartridge 36 d is different from that of others. In the color laser printer 100 , the toner cartridge 36 a is arranged at the highest position among the essential components. With the above definitions, the value of the highest point T 1 of the toner cartridge 36 a variable in the direction Y is expressed, as shown in FIG. 12 , by the following equation; T 1( y )= R 1+( N+R 1)sin θ+HIy+h sin e+D. In the right side of the above-mentioned equation, a block of the terms {R 1 +(N+R 1 )sin θ+HIy} represents a vertical distance in the direction Y between the highest point T 1 of the toner cartridge 36 a and the fixing point TT(x,y). The term h sin e represents a vertical distance in the direction Y between the fixing point TT(x,y) and the secondary image transfer point TS(x,y). The term D represents, as defined above, the vertical distance in the direction Y between the secondary image transfer point TS(x,y) and the sheet separation point BR(x,y). Here, the vertical distance D is expressed, as shown in FIG. 11 , by the following equation; D=d 2+ d 1 cos θ+d 3 sin φ. Further, in the color laser printer 100 , since the fixing unit 22 is arranged at the rightmost position in the drawing and the fixing point TT(x,y) has the greatest value in the direction X, a horizontal greatest distance TT(x) of the fixing point TT(x) is expressed, as shown in FIG. 13 , by the following equation; TT ( x )= BR ( x )+ D /tan γ+ h cos β. Based on the above equations, the color laser printer 100 preferably has the layout fulfilling a relationship T 1 (y)≦TT(x) In addition, the color laser printer 100 preferably has the layout fulfilling a relationship TT(y)≦T 3 (y) and more preferably the layout fulfilling a relationship T 4 (y)≦TT(y)≦T 3 (y). Further, the layout of the color laser printer 100 preferably fulfills a relationship HS(y)≦T 1 (y) and more preferably a relationship T 2 (y)≦TT(y)≦T 3 (y). In addition, the angle θ formed between the moving image forming bed and the horizontal line fulfills the following equation; sin θ={ T 1( y )− HIy−h sin β− D−R 1}/( N+R 1) The thus-defined angle θ is preferably set to a value within the range of 5 degrees to 25 degrees. Next, a discussion is made for a comparison between the color laser printer 100 of FIG. 7 and the background image forming apparatus of FIG. 4 . FIG. 9 is a top plan view of the color laser printer 100 of FIG. 7 and FIG. 5 is a top plan view of the background printer of FIG. 4 . The components used in the color laser printer 100 of FIG. 7 are substantially equivalent to those of the image forming apparatus of FIG. 4 . It should be clear from the illustrations of FIGS. 7 and 8 and those of FIGS. 4 and 5 that, if the machine front side is positioned in the right sides in the drawings, the color laser printer 100 has the same length of 570 mm as the other, but a shorter width of 420 mm by 55 mm and a shorter height of 468 mm by 7 mm than the other. That is, the color laser printer 100 is successfully downsized. The differences are expressed by millimeters which look miniscule. However, since most of the techniques for downsizing the image forming apparatus presently available are used in full play, even a millimeter reduction means a successful and beneficial downsizing. In the color laser printer 100 , the toners are consumable products and are replenished from the toner cartridges 36 a - 36 d to the respective development units 12 of the image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk through corresponding toner replenishing mechanisms (not shown). The toner replenishing mechanisms use a toner conveying member such as an auger (not shown), for example, which is driven by a main motor (not shown). Based on this structure, as illustrated in FIG. 7 , in the toner replenishing mechanisms, toner conveying passages between the respective toner cartridges 36 a - 36 d to the corresponding development units 12 have substantially the same length and angle relative to the corresponding development units 12 . More specifically, each of the toner cartridges 36 a - 36 d is arranged over the intermediate transfer belt 7 , with the same angle θ as the tilt angle of the moving image forming bed of the intermediate transfer belt 7 , and in parallel to the adjacent toner cartridge with substantially the same space as the space provided between adjacent two of the image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk. With the above-described structure, preconditions for the conveyance of the color toners are almost evenly set among the four toner paths from the toner cartridges 36 a - 36 d to the development units 12 of the image forming mechanisms 8 Y, 8 C, 8 M, and 8 Bk. This facilitates setting and controlling of the toner conveyance when the toner conveyance is operated with a single driving mechanism. When one of the toner cartridges 36 a - 36 d becomes empty, the cartridge needs to be exchanged with a new cartridge. Each of the toner cartridges 36 a - 36 d is exchanged by lifting the upper cover 37 upward as indicated by an arrow in FIG. 14 . When the upper cover 37 is lifted, the toner cartridges 36 a - 36 d are almost equally accessible to the user since they are arranged with the predetermined angle θ. That is, for example, the toner cartridge 36 a located at the rearmost position from the machine front is not less accessible because it is positioned at the highest horizontal level relative to others. This greatly increases operability of the toner exchanges and visual recognition, in comparison with the background image forming apparatus in which the four toner cartridges are aligned on a horizontal plain. In addition, the above-described structure of the color laser printer 100 minimizes the total length of the sheet path from the sheet supply mechanism 2 to the ejection mechanism, and easily provides a substantially straight path from the registration roller 24 to the fixing unit 22 . The straight path generally prevents a sheet jamming. Furthermore, the total sheet path can easily be accessed by opening the front cover of the color laser printer 100 , so that when a sheet jamming occurs, the jammed sheet can easily be removed from the front side with the front cover opened. As an alternative, one or more toner cartridges can be made with a greater radius than others. For example, a toner cartridge 36 e has a greater radius than the other toner cartridges 36 a - 36 c , as illustrated in FIGS. 15 and 16 . With this structure, the toner cartridge having a greater radius can contain a greater amount of toner than others and may be used for a most consumed toner, such as the black toner. As a result, a number of cartridge exchanges will be reduced. In addition, the shape of the toner cartridges 36 a - 36 d is not limited to a cylinder and can be of any shape, such as a prism shape. For example, toner cartridges 36 f have a prism shape, as illustrated in FIG. 17 . Numerous additional modifications and variations are possible in light of the above teachings. It should therefore be understood that within the scope of the appended claims, the disclosure of this patent specification may be practiced otherwise than as specifically described herein. This patent specification is based on Japanese patent application, No. JPAP2002-266629 filed on Sep. 12, 2002 in the Japanese Patent Office, the entire contents of which are incorporated by reference herein.
The present invention relates to an electrophotographic color image forming apparatus using a tandem-drum development, an indirect image-transfer method, and a vertical sheet supply path. An intermediate image-transfer member is angled relative to a horizontal line such that a rear side of the intermediate image-transfer member away from a recording sheet is lifted and a front side of the intermediate image-transfer member closer to the recording sheet is lowered. Further, image creating mechanisms of the tandem-drum development are aligned and arranged in parallel to a moving image transfer bed of the intermediate image-transfer member, such that one of the image creating mechanisms firstly forming an image faces the rear side of the moving image transfer bed and another one of the image creating mechanisms lastly forming an image faces the front side.
6
BACKGROUND OF THE INVENTION [0001] 1. Incorporation by Reference [0002] Applicant(s) hereby incorporate herein by reference, any and all U.S. patents and U.S. patent applications cited or referred to in this application. [0003] 2. Field of the Invention [0004] This invention relates generally to decorative and utility molding strips especially of the type used in residential and commercial spaces for concealing the margins between floors, walls and ceilings. [0005] 3. Description of Related Art [0006] The following art defines the present state of this field: [0007] Roberts et al., U.S. Pat. No. 5,112,548 describes an extrusion method and apparatus for producing a molding strip, which includes a decorative Mylar plastic strip located between a pair of interbonded plastic layers. The top plastic layer or topcoat is clear so that the decorative strip can be seen therethrough. A single die is utilized to produce the molding strip. The plastic layers are both preferably flexible PVC plastic which are interbonded by interfusion between adjacent surfaces while in a molten state within a bonding chamber of the die so that the plastic layers do not separate during use of the molding strip. The topcoat is interbonded with the other plastic layer or body without requiring the clear plastic to totally encapsulate the resulting molding strip. Also, preferably, a re-enforcement wire is embedded in the plastic body within the bonding chamber to give the molding strip additional strength. [0008] Azzar et al., U.S. Pat. No. 5,157,886 describes an extruded, thermoplastic baseboard elastomeric molding strip having opposed generally flat front and rear surfaces is provided with a plurality of closely vertically, spaced horizontal, parallel ribs projecting outwardly of the flat front surface over the full surface area thereof. The strip is formed of front and rear surface layers of thermoplastic material of the same durometer hardness with the front surface layer forming at least the tips of the front surface ribs being of a low density thermoplastic material and the balance of the strip being of high density thermoplastic material. The front and rear surface layers may be of contrasting colors. The rear surface of the strip is preferably formed with concave grooves separated by a multiplicity of fine, vertically spaced horizontal, parallel rearwardly projecting ribs with a rear, center rib between adjacent fine ribs, of a larger diameter than adjacent fine ribs separating the rear surface grooves. The rear surface configuration facilitates removing of excess wet adhesive and maintenance of flush adhesive mounting of the molding strip to a building vertical wall. [0009] Irrgang, U.S. Pat. No. 5,219,626 describes a molding strip, particularly for vehicles, with continuous ends formed thereon. The molding strip is a plastic injection molded part and has an integrated reinforcement, which consists of at least one metal strip. The metal strip has a plurality of cut out tongues in rows along one or both lateral edges, and which extend, in whole or in separate regions of the individual tongues, out of the plane of the metal strip. The metal strip can have shaped tongues and unshaped tongues. In a row of tongues which are arranged one behind the other, unshaped tongues alternate with tongues which extend out of the plane of the metal strip at the row of tongues. [0010] Gross et al., U.S. Pat. No. 5,286,536 describes a decorative molding strip for automobiles and the like, consisting of a polymeric body member having a stabilizing layer imbedded therein. One surface of the strip is mounted on a portion of an auto, for example, such as a bumper or a side panel, and the opposite surface is exposed and subject to impact from an outside source. The layer is made of a woven fabric, preferably of glass fibers, and allows the surface, which has been impacted to recover from indentation, thus preserving the original smooth and unblemished appearance. [0011] Logan, U.S. Pat. No. 5,398,469 describes a decorative molding for a corner formed by a ceiling and a vertical wall comprising a thin strip of flexible plastic that is secured to the wall by an attachment allowing the molding strip along its upper and lower edges to be flexible to conform with uneven surfaces in the ceiling and/or wall. In one form the strip is attached to the wall by an adhesive. In another form, a wall track and clip arrangement is utilized to provide easy removal from the wall for paint or wallpaper application. A corner element is provided in one form in which ends of the strips are adhesively secured thereto in overlapping engagement. In another embodiment, the strips are telescopically connected to the corner element. [0012] Logan et al., U.S. Pat. No. 5,457,923 describes a decorative molding for a corner formed by a ceiling and a vertical wall comprising a thin strip of flexible plastic that is secured to the wall by an attachment allowing the molding strip along its upper and lower edges to be flexible to conform with uneven surfaces in the ceiling and/or wall. In one form the strip is attached to the wall by an adhesive. In another form, a wall track and clip arrangement is utilized to provide easy removal from the wall for paint or wallpaper application. A corner element is provided in one form in which ends of the strips are adhesively secured thereto in overlapping engagement. In another embodiment, the strips are telescopically connected to the corner element. [0013] Gilmore et al., U.S. Pat. No. 5,525,384 describes a flexible ornamental or protective plastic molding strip having an inserted flexible decorative cord. The flexible molding strip, which serves as a base strip has an exposed outer surface that is usually smoothly contoured but can, if desired, be provided with longitudinally extending depressed or projecting surface decoration. In the exposed surface are one or more longitudinally extending grooves. Into each groove is inserted a flexible decorative cord, preferably of a color selected to provide an appealing visual effect, usually a color which contrasts with the color of the base strip itself. The decorative cord can be easily inserted into the groove by pressing it into place either at the factory or at the job site, to harmonize with the decor. The cord can be removed and replaced at any time desired, yet will be held securely in the groove by its contact with the walls of the groove during normal use. [0014] Gilmore, et al., U.S. Pat. No. 5,688,569 describes a flexible ornamental or protective plastic molding strip having an inserted flexible decorative cord. The flexible molding strip, which serves as a base strip has an exposed outer surface that is usually smoothly contoured but can, if desired, be provided with longitudinally extending depressed or projecting surface decoration. In the exposed surface are one or more longitudinally extending grooves. Into each groove is inserted a flexible decorative cord, preferably of a color selected to provide an appealing visual effect, usually a color which contrasts with the color of the base strip itself. The decorative cord can be easily inserted into the groove by pressing it into place either at the factory or at the job site, to harmonize with the decor. The cord can be removed and replaced at any time desired, yet will be held securely in the groove by its contact with the walls of the groove during normal use. [0015] Pallas et al., U.S. Pat. No. 6,604,331 describes an area between a wall and a floor of a building that can be covered by a baseboard-molding unit. The baseboard molding unit includes a wall-mounted track section that can be fixed to a wall by fasteners and which includes a dovetail joint element and a baseboard element that has a dovetail groove defined therein that is slidably, yet securely held on the dovetail joint element. Corner pieces are used for inside and for outside corners. [0016] Our prior art search with abstracts described above teaches: an extrusion method and apparatus for producing a molding strip, an extruded elastomeric baseboard molding strip, a molding strip, particularly for vehicles, an indention-recoverable molding strip, several decorative molding strips, a flexible molding strip having inserted decorative cord and furniture provided with such strips, and a baseboard molding strip unit. The prior art teaches that molding strips may have plural horizontal recesses in a rear surface for improved adhesive flow and removal, and that such strips may have curved decorative front surfaces, and that such strips may have an integrated stiffener strip, and that the rear surface may be formed to accommodate a mounting strip, and that such strips may be made of thin material with plural separate parts cooperating especially where an inner portion supports and provides rigidity to an outer portion covering the inner portion, and that such strips may have front surface grooves for mounting decorative strips, and that a baseboard molding may have a dovetail slot on a rear surface for intimate engagement with a dovetail supporting and mounting strip engaged with a wall surface. The present invention, in contrast provides fulfills these needs and provides further related advantages as described in the following summary. SUMMARY OF THE INVENTION [0017] The present invention teaches certain benefits in construction and use which give rise to the objectives described below. [0018] In a best mode preferred embodiment of the present invention, a molding strip having a front face and a spaced apart rear face, the front and rear faces extend between parallel top and bottom edges. The front face is formed into a decorative curvature with a frontal groove running horizontally. An insert filler is adapted for press-fitting into the frontal groove. The bottom edge is indented from the front face such that with the body oriented uprightly, and in contact with a floor surface, a frontal space is formed between the floor surface and the front face. The rear surface comprises a plurality of parallel grooves separated by at least two parallel contact edges. A cutaway surface extends from the bottom surface to a medial position on the rear face, the cutaway surface sized for receiving a smaller, prior mounted, molding strip. The molding strip is thus able to cover an existing molding strip to provide improvement to an existing construction without stripping existing moldings. [0019] A primary objective of one embodiment of the present invention is to provide an apparatus and method of use of such apparatus that yields advantages not taught by the prior art. [0020] Another objective is to assure that an embodiment of the invention is capable of covering a prior mounted molding. [0021] A further objective is to assure that an embodiment of the invention is capable of being painted without masking a floor surface and without getting paint on the floor surface. [0022] A still further objective is to assure that an embodiment of the invention is capable of receiving a decorative filler strip without the need to bond or fasten the strip while still achieving a secure mounting. [0023] A still further objective is to assure that an embodiment of the invention is capable of being mounted to a wall surface with protruding imperfections without difficulty and yet capable too of being supported by a generous amount of adhesive bonding material. [0024] Other features and advantages of the embodiments of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of at least one of the possible embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS [0025] The accompanying drawings illustrate at least one of the best mode embodiments of the present invention. In such drawings: [0026] FIGS. 1-4 are perspective views of embodiments of the invention an elongate baseboard molding strip, wherein in each view only a short portion of such a strip is depicted and particularly showing a cross section in each view; and [0027] FIG. 5 is an exploded perspective view of the embodiment of FIG. 2 . DETAILED DESCRIPTION OF THE INVENTION [0028] The above described drawing figures illustrate the present invention in at least one of its preferred, best mode embodiments, which is further defined in detail in the following description. Those having ordinary skill in the art may be able to make alterations and modifications in the present invention without departing from its spirit and scope. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example and that they should not be taken as limiting the invention as defined in the following. [0029] In one aspect of a best mode embodiment of the present invention, a baseboard molding strip apparatus 10 (“strip”) distinguishes over the prior art in several ways. Such a strip 10 is normally made of wood or of extruded plastic, but may also be made of other common and inexpensive materials by milling, molding and other well known processes. The molding strip 10 is mounted to a building vertical wall surface 20 , with a bottom edge 30 ′ of the strip 10 in contact with a building horizontal floor surface 40 . Such moldings are very common and are used to provide a finished look to a building interior. The strip 10 has a front decorative surface 12 and an opposite rear, wall contacting surface 30 as is well known. Such strips 10 are mounted to walls by nailing or gluing or both. In improving over the prior art, the bottom edge 30 ′ of the present inventive strip 10 is indented to form a horizontal frontal space 50 between the strip 10 and the floor surface 40 as shown in FIGS. 1 and 5 . The advantage and reason for this indentation will be explained in due course. [0030] A frontal horizontal slot 16 in the front decorative surface 12 has top 16 ′ and bottom 16 ″ slot edges. These edges 16 ′, 16 ″ diverge inwardly to better engaged a decorative insert filler strip 70 that may be used to provide a customized appearance to the strip 10 . The rear, wall contacting surface 30 comprises a plurality of horizontal, vertically spaced contact edges 14 ′ all of which align along a plane so as to commonly contact the wall surface 20 . These edges 14 ′ are interspersed by a plurality of horizontal, vertically spaced concave grooves 14 ″ for retaining an adhesive (not shown) used for mounting the strip 10 . Such grooves 14 ″ enable the surface 30 to avoid difficulties with minor wall protrusions such as pimples and also to hold a greater amount of adhesive for an improved engagement with the wall to which it is attached. [0031] Preferably, the strip 10 has a cutaway surface 18 extending from the bottom edge 30 ′, upwardly to a medial position 60 on the rear surface 30 , such that with the rear, wall contacting edges 14 ′ abutting the building vertical wall surface 20 , and with the bottom edge 30 ′ abutting the building horizontal floor surface 40 , a lesser sized, existing molding strip 5 mounted to the building vertical wall surface 20 , is concealed within the cutaway surface 18 . This provides the great advantage of being able to install the strip 10 without removing prior mounted molding of a smaller size. [0032] Preferably, the present invention further comprises the insert filler 70 which is adapted with divergent filler side edges 72 and 74 for positive engagement within the frontal horizontal slot 16 . This is accomplished by tapering the filler side edges 72 and 74 to correspond with edges 16 ′ and 16 ″. Such diverging edges are preferably at an angle of between 1 and 3 degrees so as to assure a positive lock of the filler 70 within the slot 16 while still enabling engagement by simply pushing the filler 70 into the slot 16 where it snaps into place and is held without adhesive or nails, etc. [0033] The indented bottom edge 30 ′ of the strip 10 provides the advantage, when installing the strip 10 , of providing a solid footing to the strip 10 , while enabling the strip 10 to be finished by staining, painting, or other surface finishing, without such finishing material inadvertently coming into contact with the building horizontal floor surface 40 . Thus, a painter's barrier (not shown) such as a piece of cardboard or similar flat and stiff sheet stock material, may be held under the strip 10 during painting, etc. to assure that the floor surface 40 is not contacted. Such a barrier is moved along the strip 10 as finishing proceeds. This avoids the time and expense of using masking tape, which, of course, must be carefully placed and thereafter removed. [0034] FIG. 1 shows an embodiment of the invention with filler 70 , with indent space 50 and with parallel grooves 14 ″. FIG. 2 shows a similar strip 10 having also cutout 18 . FIG. 3 shows a similar strip 10 with an alternate filler 70 showing that such a filler 70 may be made in various sizes and with varying decorative features. FIG. 4 shows the strip 10 of FIG. 3 with the cutout 18 showing that the cutout 18 may be included or not. [0035] The enablements described in detail above are considered novel over the prior art of record and are considered critical to the operation of at least one aspect of one best mode embodiment of the instant invention and to the achievement of the above described objectives. The words used in this specification to describe the instant embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification: structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use must be understood as being generic to all possible meanings supported by the specification and by the word or words describing the element. [0036] The definitions of the words or elements of the embodiments of the herein described invention and its related embodiments not described are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the invention and its various embodiments or that a single element may be substituted for two or more elements in a claim. [0037] Changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalents within the scope of the invention and its various embodiments. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The invention and its various embodiments are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted, and also what essentially incorporates the essential idea of the invention. [0038] While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims and it is made clear, here, that the inventor(s) believe that the claimed subject matter is the invention.
A molding strip has a front surface and a spaced apart rear surface, the front and rear surfaces extending between parallel top and bottom edges. The front surface is decorative with a horizontal groove for accepting a decorative filler strip. The bottom surface is indented from the front surface to form a space between the molding strip and the floor below it. The rear surface comprises a plurality of parallel grooves separated by horizontal contact edges. A cutaway surface extends from the bottom edge to a medial position on the rear surface for concealing a lesser sized molding strip.
4
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of Korean Patent Application No. 10-2008-0123183 filed on Dec. 5, 2008, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference. BACKGROUND 1. Field The present invention relates to a method of controlling a washing machine. More particularly, the present invention relates to a method of controlling a washing machine, capable of detecting clothes contained in a drum by rotating the drum. 2. Description of the Related Art In general, a washing machine is a device used to remove dirt stained on clothes. According to such a washing machine, after supplying water into a washing tub such that the clothes are submerged in water, a predetermined amount of detergent is dissolved in the water to remove contaminants stained on the clothes through a chemical reaction with detergent and the washing tub having the clothes is rotated while generating friction and vibration against the clothes to mechanically remove the contaminants from the clothes. In such a washing machine, after the washing operation on the clothes has been completed, the contaminants removed from the clothes or detergent residues may remain in the tub or the drum, and if the washing machine is repeatedly used for a long period of time, germ and mold may inhabit the inside of the tub. Such a contamination in the washing machine causes a bad odor, increases germs and re-contaminates clothes, thereby exerting bad influence upon the human body. Accordingly, recently, a barrel cleaning course is added to a method of operating the washing machine to remove the contaminants or the detergent residue remaining in the tub or drum. Such a barrel cleaning course generally includes an operation of removing the contaminants remaining in the tub or drum using hot water or steam and an operation of rinsing the tub or drum by providing water inside the tub or drum. SUMMARY Accordingly it is an aspect of the present invention to provide a method of controlling a washing machine, capable of detecting clothes contained in a drum by rotating the drum. It is another aspect of the present invention to provide a method of controlling a washing machine, capable of detecting clothes contained in a drum by rotating the drum and determining whether a tub cleaning is performed under the detected result. Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention. The foregoing and and/or other aspects are achieved by providing a method of controlling a washing machine, which includes supplying a predetermined amount of water when a barrel cleaning is executed, soaking an interior of a drum in water, draining water after the interior of the drum has been soaked in the water, and detecting clothes contained in the drum by rotating the drum. According to an aspect, in the detecting of the clothes, the clothes contained in the drum may be detected by estimating inertia of the drum or inertia of the drum and the clothes. According to an aspect, the method of controlling the washing machine further may include comparing the estimated inertia with an allowable inertia. According to an aspect, determination whether the drum contains the clothes may be performed by comparing the estimated inertia with the allowable inertia. According to an aspect, an rpm of the drum may be increased up to a first reference value and the rpm of the drum is maintained at the first reference value for a predetermined time, and then the rpm of the drum is increased up to a second reference value after the predetermined time has lapsed, thereby estimating the inertia. According to an aspect, the inertia may be estimated by using a torque that is input to accelerate rotation of the drum, an accelerating time and a difference between the first reference value and the second reference value. According to an aspect, in the detecting of the clothes, the clothes contained in the drum may be detected by estimating weight of the drum or weight of the drum and the clothes. According to an aspect, the method of controlling the washing machine may further include comparing the estimated weight with an allowable weight. According to an aspect, determination whether the drum contains the clothes may be performed by comparing the estimated weight with the allowable weight. According to an aspect, an rpm of the drum may be increased up to a first reference value and the rpm of the drum is maintained at the first reference value for a predetermined time, and then the rpm of the drum is increased up to a second reference value after the predetermined time has lapsed, thereby estimating the weight. According to an aspect, the weight may be estimated by using a torque that is input to accelerate rotation of the drum, an accelerating time and a difference between the first reference value and the second reference value. It is another aspect of the present invention to provide a method of controlling a washing machine, which includes detecting a water level in a drum when a barrel cleaning is executed, supplying or draining water according to the detected water level such that a water level reaches a reference water level, soaking an interior of the drum in water, draining water after the interior of the drum is soaked in water, and detecting clothes contained in the drum by rotating the drum. According to an aspect, in the detecting of the clothes, the clothes contained in the drum may be detected by estimating inertia of the drum or inertia of the drum and the clothes. According to an aspect, the method of controlling the washing machine may include comparing the estimated inertia with an allowable inertia. According to an aspect, determination whether the drum contains the clothes may be performed by comparing the estimated inertia with the allowable inertia. According to an aspect, an rpm of the drum may be increased up to a first reference value and the rpm of the drum is maintained at the first reference value for a predetermined time, and then the rpm of the drum is increased up to a second reference value after the predetermined time has lapsed, thereby estimating the inertia. According to an aspect, the inertia may be estimated by using a torque that is input to accelerate rotation of the drum, an accelerating time and a difference between the first reference value and the second reference value. According to an aspect, in the detecting of the clothes, the clothes contained in the drum may be detected by estimating weight of the drum or weight of the drum and the clothes. According to an aspect, determination whether the drum contains the clothes may be performed by comparing the estimated weight with the allowable weight. According to an aspect, an rpm of the drum may be increased up to a first reference value and the rpm of the drum is maintained at the first reference value for a predetermined time, and then the rpm of the drum is increased up to a second reference value after the predetermined time has lapsed, thereby estimating the weight. According to an aspect, the weight may be estimated by using a torque that is input to accelerate rotation of the drum, an accelerating time and a difference between the first reference value and the second reference value. It is another aspect of the present invention to provide a method of controlling a washing machine, which includes estimating inertia or weight of a drum or the drum and clothes by rotating the drum when a barrel cleaning is executed, detecting if the drum contains the clothes according to the estimated inertia or weight, and executing a barrel cleaning stopping mode if it is detected that the clothes are contained in the drum. According to an aspect, the method of controlling the washing machine may further include soaking the drum or soaking the drum and the clothes in water after a predetermined amount of water is supplied into the drum. According to an aspect of the present invention, the method of controlling the washing machine may further include draining remaining water after water soaks in the drum or the drum and the clothes. According to an aspect, in the detecting of the clothes, the estimated inertia may be compared with an allowable inertia, thereby detecting if the drum contains the clothes. According to an aspect, in the detecting of the clothes, if the estimated inertia is larger than the allowable inertia, it may be determined that the drum contains the clothes. According to an aspect, in the detecting of the clothes, the estimated weight may be compared with an allowable weight, thereby detecting if the drum contains the clothes. According to an aspect, in the detecting of the clothes, if the estimated weight is larger than the allowable weight, it may be determined that the drum contains the clothes. According to an aspect, in the barrel cleaning stopping mode, if the clothes are detected in the drum, an alarming signal may be generated. According to an aspect, in the barrel cleaning stopping mode, if the clothes are detected in the drum, a washing operation may be performed. According to an aspect, in the barrel cleaning stopping mode, if the clothes are detected in the drum, the barrel cleaning may be stopped. As described above, the clothes contained in the drum may be detected by estimating inertia and weight of clothes to determine whether to perform a barrel cleaning. Accordingly, vibration and noise are prevented from being generated in the washing machine, and accident due to the movement of the washing machine is prevented. In addition, even though an additional barrel cleaning safety apparatus may not be provided, when a barrel cleaning execution is ordered, the clothes contained in the drum are easily detected and it is determined whether to perform the barrel cleaning process. Accordingly, vibration and noise are reduced during the barrel cleaning process. BRIEF DESCRIPTION OF THE DRAWINGS These and/or other aspects and advantages of the invention 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 representing a structure of a washing machine according to an embodiment; FIG. 2 is a block diagram of a washing machine according to the embodiment; FIG. 3 is a graph illustrating an rpm variation of a drum when inertia or weight of the drum of the washing machine is estimated according to the embodiment; FIG. 4 is a graph representing a result of inertia detected according to the embodiment; FIG. 5 is a flowchart representing a process of detecting inertia or weight of the drum of the washing machine according to a first embodiment; and FIG. 6 is a flowchart representing a process of detecting inertia or weight of the drum of the washing machine according to a second embodiment. DETAILED DESCRIPTION OF EMBODIMENTS Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below to explain the present invention by referring to the figures. Hereinafter, an embodiment will be described in detail with respect to accompanying drawings. FIG. 1 is a sectional view representing a structure of a washing machine according to an embodiment. As shown in FIG. 1 , a washing machine according to an embodiment includes a drum-type water tub 11 , which is installed inside a body 10 to contain water therein, and a rotating drum 12 rotatably installed inside the water tub 11 . A motor 15 is installed at an outer side of a rear surface 11 c of the water tub 11 to rotate a rotary shaft 13 connected to the rotating drum 12 such that washing, rinsing and dehydration processes are performed. A heater 16 is installed at an inner lower side of the water tub 11 to heat the water provided in the water tub 11 . A detergent supply apparatus 18 is provided at an upper part of the water tub 11 to provide detergent. A water supply apparatus 20 , which includes a water supply pipe 21 to provide water to the water tub 11 , and a water supply valve 22 , which is installed on the water supply pipe 21 to control water supply of the water supply pipe 21 , are installed at the upper part of the water tub 11 . A drain apparatus 19 is provided at a lower portion of the water tub 11 to drain water to the outside. The drain apparatus 19 includes a water drain pipe 19 a , a water drain valve 19 b to intermittently drain water to the outside, and a drain pump 19 c for pumping water out of the water tub 11 . A temperature sensor 23 is installed inside the water tub 11 to measure the temperature of water. An opening 17 b , which is open corresponding to an opening 12 b of the rotating drum 12 and an opening 11 b of the water tub 11 , is installed at a front surface of the body 10 such that clothes are input into the rotating drum 12 or output from the rotating drum 12 . A door 17 is installed at the opening 17 b to open and close the opening 12 b. A control panel 24 is installed at an upper end of the front surface of the body to allow a user to input a command for a washing operation, a rinsing operation and dehydration operation through the control panel 24 . Reference numeral 29 represents a water level detection unit to detect a water level of water provided into the water tub 11 . The water level detection unit 29 includes a water level detection apparatus 25 connected at one side of the drain apparatus 19 , an air chamber 26 , a water level detection tube 27 having a lower end connected to one side of the air chamber 26 , and a water level sensor 28 , which is connected to an upper end of the water level detection tube 27 to detect pressure of air contained in the water level detection tube 27 such that the water level is detected. The air chamber 26 is communicated with a lower end of the water level detection apparatus 25 and is filled with air to which pressure is applied depending on the water level in the water level detection apparatus 25 . Meanwhile, when a barrel cleaning is performed, the water level sensor 28 detects the level of water filled in the water tub 11 and transmits the information thereof to a control unit 31 . FIG. 2 is a block diagram of a washing machine according to the embodiment. As shown in FIG. 2 , the washing machine according to the embodiment includes an input unit 24 , the water level detection unit 29 , the control unit 31 and a driving unit 32 . The input unit 24 corresponds to the control panel 24 , which allows the user to input the command for the washing, rinsing and dehydration operations or a particular course such as a barrel cleaning course. If operation information is input by a user, the input unit 24 transmits the information to the control unit 31 . The water level detection unit 29 includes the water level detection apparatus 25 connected at one side of the drain apparatus 19 , the air chamber 26 , the water level detection tube 27 having a lower end connected to one side of the air chamber 26 , and the water level sensor 28 , which is connected to an upper end of the water level detection tube 27 to detect pressure of air contained in the water level detection tube 27 such that the water level is detected. The air chamber 26 is communicated with the lower end of the water level detection apparatus 25 and is filled with air to which pressure is applied depending on the water level in the water level detection apparatus 25 . The water level detection unit 29 detects the water level of the drum 12 to transmit the information thereof to the control unit 31 . An rpm (revolution per minute) detection unit 33 detects the rpm of the motor and transmits the information thereof to the control unit 31 . The control unit 31 corresponds to a microcomputer which controls the washing machine according to the operational information input through the input unit 24 . The control unit 31 stores the amount of clothes, the rpm of the motor 15 , an operating time (an on-off time of the motor) and a washing time in a selected washing course and controls the overall operation of the washing machine. In addition, when the barrel cleaning is performed, the control unit 31 estimates inertia or weight generated by the drum 12 or the clothes of drum 12 by rotating the drum 12 and determines whether the barrel cleaning is performed according to the estimated inertia or weight. In detail, if the user presses a start button for the barrel cleaning course, a safety operation starts to determine whether the clothes exist in the drum 12 . Hereinafter, the safety operation will be described. First, if the barrel cleaning is executed, the control unit 31 supplies a predetermined amount of water, for example, 10 L of water, into the drum, and rotates the drum 12 for a predetermined time to uniformly soak the clothes in the water. After that, in order to allow the clothes to be attached to an inner wall of the drum 12 , the control unit 31 drives the drum 12 with an rpm having a first reference value, for example, 90 rpm, and the rpm of the drum 12 is maintained for a predetermined time such that the clothes sticking to the inner wall of the drum are uniformly spread. Then, the rpm of the drum is increased up to a second reference value, for example, 100 to 140 rpm, and the inertia or weigh of the drum 12 is estimated using torque input to increase the speed of the drum 12 from the first reference value to the second reference value, an accelerating time, and a difference between a final speed corresponding to the second reference value and an initial speed corresponding to the first reference value. The detailed equation will be described below with reference to FIG. 3 . Meanwhile, the barrel described above represents the water tub 11 and the drum 12 of the washing machine. Meanwhile, the driving unit 32 drives the motor 15 , the water supply valve 22 and the drain pump 19 c according to a control signal of the control unit 31 . FIG. 3 is a graph illustrating an rpm variation of a drum when inertia or weight of the drum of the washing machine is estimated according to the embodiment of the present invention. As shown in FIG. 3 , when the barrel cleaning is executed, the rpm of the drum 12 is adjusted corresponding to a water supply operation (a), a soaking operation (b), a water drain operation (c) and an inertia estimation operation (d) such that the inertia or the weight generated by the clothes contained in the drum 12 is estimated. That is, in operation (a), fixed quantity of water (for example, 10 L) is supplied into the inside of the drum 12 while rotating the drum 12 at 47 rpm. In operation (b), the drum 12 is rotated for a predetermined time (for example, 2 minutes) at 47 rpm such that the clothes are uniformly soaked in the water. Then, in operation (c), after the water soaks into the clothes contained in the drum 12 in operations (a) and (b), the remaining water is drained. In operation (d), the rpm is variously adjusted to estimate the inertia or weight of the drum 12 . That is, in operation (d), the rpm of the drum 12 is increased up to the first reference value, that is, 90 rpm, which is sufficient for allowing the clothes contained in the drum 12 to stick to the inner wall of the drum 12 , and then the rpm is maintained in the first reference value for a predetermined time such that the clothes uniformly stick to the inner wall of the drum 12 . After a predetermined time has lapsed, since the clothes in the drum 12 uniformly stick to the inner wall of the drum 12 , the rpm of the drum 12 is increased up to the second reference value, that is, 100 to 140 rpm, to estimate the inertia. However, the reference value described above is illustrative purposes only, and can be changed according to the characteristics of the washing machine. Meanwhile, the detailed equation used to estimate the inertia of the drum 12 or the inertia of the drum 12 and the clothes using the reference value is as follows. J*a=T   1 a=Δw/Δt   2 J=inertia a=rotational acceleration of the drum T=input torque Δw=variation of angular velocity of the drum=difference between the first reference value and the second reference value Δt=time variation According to the above equations, multiplication of the inertia J and the rotational acceleration a of the drum 12 corresponds to the input torque T. The input torque T is a physical factor causing the drum 12 to rotate, and the input torque T is set as a constant by the control unit 31 . The rotational acceleration is variation of the rotational speed of the drum 12 with respect to time and is measured by the rpm detection unit 33 . Accordingly, the inertia is detected through the equation described below. J=T *(Δ t/Δw )=constant*(Δ t/Δw )  3 That is, if the control unit 31 receives information (Δw/Δt) on the angular velocity of the drum 12 with respect to a predetermined time from the rpm detection unit 33 , the control unit 33 multiplies the information on the angular velocity by the torque T having a constant, thereby obtaining the inertia J. Meanwhile, the weight estimated by the drum 12 or the drum 12 and the clothes can be obtained through the equation described below using the reference value. m=k*J   4 k=constant m=weight As described the above equation, the weight estimated by the drum 12 or the drum 12 and the clothes can be obtained by multiplying the estimated inertia J by the constant k. The above Equation 4 represents that the estimated inertia is proportional to the estimated weight, and the constant k is determined by a designer through various experiments in consideration of a factor such as a distance from a center of the drum 12 and the inner wall. However, when an allowable weight to be described below is determined, the value of the constant k must be considered. In detail, if the constant k is set, a weight estimated by multiplying the constant k by an allowable inertia is set as the allowable weight and is used to detect the distribution of the clothes in the drum 12 . FIG. 4 is a graph representing inertia estimated according to the embodiment. FIG. 4 is a result of inertia estimated according to the increase of the number of towels in the drum of the washing machine, and the estimated inertia is getting larger as the number of the towels in the drum 12 is increased. In addition, the inertia estimated by the clothes in the drum 12 is proportional to the weight of the clothes. Meanwhile, dry clothes have small inertia. Accordingly, the clothes in the drum 12 are soaked in the water such that the inertia is increased, thereby reducing an error of measurement. FIG. 5 is a flowchart representing a process of detecting inertia or weight of the drum of the washing machine according to a first embodiment of the present invention. As shown in FIG. 5 , after the barrel cleaning starts, the control unit 31 supplies water inside the drum 12 by a predetermined water level and the drum 12 is rotated with a predetermined rpm (for instance, 47 rpm). A predetermined quantity of water is supplied to soak the clothes in the water such that the error is reduced when the inertia or weight is estimated (s 10 ). Then, the drum 12 is rotated at a predetermined velocity, thereby uniformly soaking the clothes in the water. For example, after 10 L of water has been supplied in operation 10 , the drum 12 is rotated forward and backward for about 2 minutes at a predetermined velocity, for example, 47 rpm, which is sufficient for moving up and dropping down the clothes (s 20 ). After the clothes have been uniformly soaked in the water, the remaining water is drained. That is, water is drained after the drum 12 has been rotated for a predetermined period of time. Thus, in a state in which the drum 12 does not contain the water except for the water soaked into the clothes, the drum 12 rotates and is accelerated, thereby draining water to estimated the inertia of the drum 12 containing the clothes (s 30 ). Then, the motor 15 is driven such that the rpm of the drum 12 is increased up to the first reference value. That is, the rotational velocity of the drum 12 is increased up to a predetermined velocity, which is sufficient for allowing the clothes in the drum 12 to stick to the inner wall of the drum 12 , that is, the first reference value (for example, 90 rpm) set by a manufacturer (s 40 ). Then, the rotational velocity of the drum is maintained at the first reference value in a state that the rotational velocity of the drum 12 reaches the first reference value. This process is performed such that the clothes stick to the inner wall of the drum 12 when the rpm of the drum 12 is increased up to the first reference value, and the clothes are uniformly spread on the inner wall of the drum 12 when the velocity of the drum 12 is maintained in the first reference value for a predetermined time (s 50 ). After the clothes are uniformly spread while sticking to the inner wall of the drum 12 , the rotational velocity of the drum 12 is increased up to the second reference value. This process is performed to obtain a difference between the initial velocity corresponding to the first reference value and the final velocity corresponding to the second reference value and the accelerating time such that the inertia or weight is estimated through the above Equations 3 and 4 shown in FIG. 3 (s 60 ). After that, the control unit 31 puts the accelerating time measured when the velocity of the drum 12 is increased from the first reference value to the second reference value in operation 60 , the difference between the initial velocity and the final velocity and the torque input during the acceleration in Equation 3, thereby estimating the inertia caused by the drum 12 and the clothes. In addition, the control unit 31 puts the accelerating time measured when the velocity of the drum 12 is increased from the first reference value to the second reference value in operation s 60 , the difference between the initial velocity and the final velocity, the torque input during the acceleration and the constant in Equation 4, thereby estimating the weight of the drum 12 of the drum 12 and the clothes (s 70 ). Then, the allowable inertia is compared with the estimated inertia obtained in operation 70 . The allowable inertia is set by the manufacturer based on the inertia estimated when the drum 12 does not contain the clothes. If an estimated inertia exceeds a predetermined level, noise and vibration occur or the washing machine is shaken when the barrel cleaning is performed. In addition, the control unit 31 compares the estimated weight with the allowable weight. Similarly to the allowable inertia, the allowable weight can be set by the manufacturer based on the weight estimated when the drum 12 does not contain the clothes. Otherwise, as described above with reference to FIG. 3 , the estimated weight obtained by multiplying the constant k by the allowable inertia can be determined as the allowable weight (s 80 ). After that, if the estimated inertia is determined to be larger than the allowable inertia, a stopping mode is performed. The stopping mode according to the embodiment of the present invention includes a first mode to raise an alarm signal the user through a display and to stop the barrel cleaning operation and a second mode to wash the clothes contained in the drum 12 . In the case of the first mode, the user must take out the clothes contained in the drum 12 and resumes the barrel cleaning. In the case of the second mode, the normal washing operation including water supply, washing, rinsing and draining is performed, so the clothes existing in the drum 12 are washed. If the amount of clothes is small, the barrel including the water tub and the drum is washed. Meanwhile, if the estimated weight is larger than the allowable weight, the barrel cleaning is performed similarly to the barrel cleaning performed when the estimated inertia is larger than the allowable inertia (s 90 ). Meanwhile, when the estimated inertia is smaller than the allowable inertia, the barrel cleaning is performed. In addition, when the estimated weight is smaller than the allowable weight, the barrel cleaning is performed similarly to the barrel cleaning performed when the estimated weight is smaller than the allowable weight. Meanwhile, the barrel cleaning can be variously performed by supplying water in the water tub, heating the water to a predetermined sterilization temperature and then rotating the drum 12 such that the heated water is distributed over the entire area of the water tub or the drum 12 . Otherwise, the barrel cleaning can be performed using steam (s 100 ). FIG. 6 is a flowchart representing a process of detecting inertia or weight of the drum 12 of the washing machine according to a second embodiment. When compared with the first embodiment, the second embodiment is different from the first embodiment in that it is checked whether water exists in the drum 12 during the barrel cleaning to determine the supply of water according to the existence of water. As shown in FIG. 6 , when the barrel cleaning starts, the control unit 31 receives the information on a water level of the drum 12 through the water level detection unit 29 and compares the information on the water level of the drum 12 with a reference water level determined by the user. Since the clothes must be uniformly socked in water in the soaking operation to reduce the error generated when measuring the inertia or weight of the clothes in the drum 12 , the process of comparing the water levels is necessary, and the reference water level represents a level of water supplied to soak the clothes in the drum 12 in the soaking operations (s 100 and s 110 ). If the water level detected by the water level detection unit 29 is determined to be higher than the water level required to soak the clothes during the barrel cleaning, the water in the drum 12 is drained such that the water level reaches the reference water level (s 120 ). Meanwhile, in operation s 110 , the water level detected by the water level detection unit 29 is determined to be lower than the water level required to soak the clothes during the barrel cleaning, water is additionally supplied. Since the clothes must be uniformly soaked in water to reduce the error generated when measuring the inertia or weight of the clothes in the drum 12 , the process of supplying water is necessary (s 130 ). Meanwhile, since remaining operations s 140 to s 220 according to the second embodiment are identical to operations s 20 to s 100 , the description thereof will be omitted. Although few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and sprit of the invention, the scope of which is defined in the claims and their equivalents.
A method of controlling a washing machine, capable of detecting clothes contained in the washing machine by rotating a drum. The method includes supplying a predetermined amount of water when a barrel cleaning is executed, soaking an interior of a drum in water, draining water after the interior of the drum has been soaked in the water, and detecting clothes contained in the drum by rotating the drum. Whether to perform a barrel cleaning is determined according to the existence of the clothes in the drum, so that vibration and noise are prevented from being generated in the washing machine, and accident due to the movement of the washing machine is prevented.
3
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a turbo-molecular pump for evacuating gas with a rotor that rotates at a high speed, and more particularly to a turbo-molecular pump having a radial turbine blade pumping section in a casing. 2. Description of the Related Art FIG. 12 of the accompanying drawings shows a conventional turbo-molecular pump having a radial turbine blade pumping section in a casing. As shown in FIG. 12, the conventional turbo-molecular pump comprises a rotor R and a stator S which are housed in a casing 10 . The rotor R and the stator S jointly make up an axial turbine blade pumping section L 1 and a radial turbine blade pumping section L 2 . The stator S comprises a base 14 , a stationary cylindrical sleeve 16 vertically mounted centrally on the base 14 , and stationary components of the axial turbine blade pumping section L 1 and the radial turbine blade pumping section L 2 . The rotor R comprises a main shaft 18 inserted in the stationary cylindrical sleeve 16 , and a rotor body 20 fixed to the main shaft 18 . Between the main shaft 18 and the stationary cylindrical sleeve 16 , there are provided a drive motor 22 , and upper and lower radial bearings 24 and 26 provided above and below the drive motor 22 . An axial bearing 28 is disposed at a lower portion of the main shaft 10 , and comprises a target disk 28 a mounted on the lower end of the main shaft 18 , and upper and lower electromagnets 28 b provided on the stator side. Further, touchdown bearings 29 a and 29 b are provided at upper and lower portions of the stationary cylindrical sleeve 16 . With this arrangement, the rotor R can be rotated at a high speed under 5 -axis active control. The rotor body 20 in the axial turbine blade pumping section L 1 has disk-like rotor blades 30 integrally provided on an upper outer circumferential portion thereof. In the casing 10 , there are provided stator blades 32 disposed axially alternately with the rotor blades 30 . Each of the stator blades 32 has an outer edge clamped by stator blade spacers 34 and is thus fixed. Each of the rotor blades 30 has a wheel-like configuration which has a hub at an inner circumferential portion thereof, a frame at an outer circumferential portion thereof, and inclined blades (not shown) provided between the hub and the frame and extending in a radial direction. Thus, the turbine blades 30 are rotated at a high speed to make an impact on gas molecules in an axial direction for thereby evacuating gas. The radial turbine blade pumping section L 2 is provided downstream of, i.e. below the axial turbine blade pumping section L 1 . In the radial turbine blade pumping section L 2 , the rotor body 20 has disk-like rotor blades 36 integrally provided on an outer circumferential portion thereof in the same manner as the axial turbine blade pumping section L 1 . In the casing 10 , there are provided stator blades 38 disposed axially alternately with the rotor blades 36 . Each of the stator blades 38 has an outer edge clamped by stator blade spacers 40 and is thus fixed. Each of the stator blades 38 is in the form of a follow disk, and as shown in FIGS. 13A and 13B, each of the stator blades 38 has spiral ridges 46 which are formed in the front and backside surfaces thereof and extend between a central hole 42 and an outer circumferential portion 44 , and spiral grooves 48 whose widths are gradually broader radially outwardly and which are formed between the adjacent ridges 46 . The spiral ridges 46 on the front surface, i.e. upper surface of the stator blade 38 are configured such that when the rotor blade 36 is rotated in a direction shown by an arrow A in FIG. 13A, gas molecules flow inwardly as shown by a solid line arrow B. On the other hand, the spiral ridges 46 on the backside surface, i.e. lower surface of the stator blade 38 are configured such that when the rotor blade 36 is rotated in a direction shown by the arrow A in FIG. 13A, gas molecules flow outwardly as shown by a dotted line arrow C. Each of the stator blade 38 is usually composed of two half segments, or three or more divided segments. The stator blades 38 are assembled by interposing the stator blade spacers 40 so that the stator blades 38 alternate with the rotor blades 36 , and then the completed assembly is inserted into the casing 10 . With the above configuration, in the radial turbine blade pumping section L 2 , a long evacuation passage extending in zigzag from top to bottom between the stator blades 38 and the rotor blades 36 is constructed within a short span in the axial direction, thus achieving high evacuation and compression performance without making the radial turbine blade pumping section L 2 long in the axial direction. In the radial turbine blade pumping section L 2 , the outer diameter D 1 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 is set to the same dimension in all stages, and the inner diameter D 2 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 is set to the same dimension in all stages. However, in the case of the conventional turbo-molecular pump having the radial turbine blade pumping section L 2 , as shown in FIG. 14, the gap G 1 between the stator blade 38 located at the first stage in the radial turbine blade pumping section L 2 and the rotor blade 30 located immediately above this first-stage stator blade 38 and at the lowermost stage in the axial turbine blade pumping section L 1 is constant. Therefore, the cross-sectional area of the flow passage extending along the upper surface of the stator blade 38 toward the inner circumferential side of the stator blade 38 , i.e. the inner circumferential side of the radial turbine blade pumping section L 2 decreases drastically in proportion to the radius of the stator blade 38 . Consequently, the gas is prevented from flowing smoothly to the inner circumferential side of the radial turbine blade pumping section L 2 to cause stagnation of the gas. Further, when the gas turns its flow direction from the axial direction to the radial direction, the gas cannot be smoothly flowed to be stagnated, thus lowering the evacuation performance of the pump. SUMMARY OF THE INVENTION The present invention has been made in view of the above drawbacks in the conventional turbo-molecular pump. It is therefore an object of the present invention to provide a turbo-molecular pump which can create smooth gas flow therein and prevent the evacuation performance from lowering. According to a first aspect of the present invention, there is provided a turbo-molecular pump comprising: a casing; a stator fixedly mounted in the casing and having stator blades; a rotor rotatably provided in the casing and having rotor blades, the rotor blades alternating with the stator blades; and a radial turbine blade pumping section having a spiral ridge-groove section provided on at least one of surfaces, facing each other, of the stator blade and the rotor blade; wherein at least one of the stator blade and the rotor blade which are located at a first stage of the radial turbine blade pumping section has such a shape that the at least one of the stator blade and the rotor blade is smaller in thickness in a direction of gas flow. With the above arrangement, at least one of the cross-sectional area of the flow passage defined between the stator blade at the first stage in the radial turbine blade pumping section and the rotor blade located immediately above this first-stage stator blade and at the lowermost stage in the axial turbine blade pumping section and the cross-sectional area of the flow passage defined between the rotor blade at the first stage in the radial turbine blade pumping section and the stator blade located immediately above this first-stage rotor blade and at the lowermost stage in the axial turbine blade pumping section is prevented from being drastically smaller in the direction of gas flow. Thus, the gas flowing from an upstream side into the radial turbine blade pumping section can be guided smoothly toward the inner circumferential side of the radial turbine blade pumping section. According to a second aspect of the present invention, there is provided a turbo-molecular pump comprising: a casing; a stator fixedly mounted in the casing and having stator blades; a rotor rotatably provided in the casing and having rotor blades, the rotor blades alternating with the stator blades; and a radial turbine blade pumping section having a spiral ridge-groove section provided on at least one of surfaces, facing each other, of the stator blade and the rotor blade; wherein an outer diameter of the rotor at its portion facing an inner circumferential surface. of a stator blade at a first stage in the radial turbine blade pumping section is smaller than an outer diameter of the rotor at its portion facing an inner circumferential surface of a stator blade at any one of stages subsequent to the first stage. With this arrangement, the cross-sectional area of the flow passage in an axial direction defined between the inner circumferential surface of the stator blade at the first stage and the outer circumferential surface of the rotor at its portion facing the inner circumferential surface of this first-stage stator blade is enlarged for thereby guiding the gas toward a radial direction in flow passages upstream and downstream of the flow passage in the axial direction. According to a third aspect of the present invention, there is provided a turbo-molecular pump comprising: a casing; a stator fixedly mounted in the casing and having stator blades; a rotor rotatably provided in the casing and having rotor blades, the rotor blades alternating with the stator blades; and a radial turbine blade pumping section having a spiral ridge-groove section provided on at least one of surfaces, facing each other, of the stator blade and the rotor blade; wherein one of an inner diameter of the stator and an outer diameter of the spiral ridge-groove section at its portion facing an outer circumferential surface of a rotor blade at a first stage in the radial turbine blade pumping section is larger than an inner diameter of the stator and an outer diameter of the spiral ridge-groove section at its portion facing an outer circumferential surface of a rotor blade at any one of stages subsequent to the first stage. With this arrangement, the cross-sectional area of the flow passage in an axial direction defined between the outer circumferential surface of the rotor blade at the first stage and the inner circumferential surface of the stator at its portion facing the outer circumferential surface of this first-stage rotor blade or the outer diameter of the spiral ridge-groove section is enlarged for thereby guiding the gas toward a radial direction in flow passages upstream and downstream of the flow passage in the axial direction. Generally, the inner circumferential surface of the stator at its portion facing the outer circumferential surface of this first-stage rotor blade and the outer diameter of the spiral ridge-groove section have the same dimension. According to a fourth aspect of the present invention, there is provided a turbo-molecular pump comprising: a casing; a stator fixedly mounted in the casing and having stator blades; a rotor rotatably provided in the casing and having rotor blades, the rotor blades alternating with the stator blades; and a radial turbine blade pumping section having a spiral ridge-groove section provided on at least one of surfaces, facing each other, of the stator blade and the rotor blade; wherein an outer diameter of the rotor at its portion facing an inner circumferential surface of a stator blade at a first stage in the radial turbine blade pumping section is smaller than an outer diameter of the rotor at its portion facing an inner circumferential surface of a stator blade at any one of stages subsequent to the first stage; one of an inner diameter of the stator and an outer diameter of the spiral ridge-groove section at its portion facing an outer circumferential surface of a rotor blade at a first stage in the radial turbine blade pumping section is larger than an inner diameter of the stator and an outer diameter of the spiral ridge-groove section at its portion facing an outer circumferential surface of a rotor blade at any one of stages subsequent to the first stage. The above and other objects, features, and advantages of the present invention will be apparent from the following description when taken in conjunction with the accompanying drawings which illustrates preferred embodiments of the present invention by way of example. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of a turbo-molecular pump according to a first embodiment of the present invention; FIG. 2 is an essential part of the turbo-molecular pump shown in FIG. 1; FIG. 3 is a cross-sectional view of a turbo-molecular pump according to a second embodiment of the present invention; FIG. 4 is an essential part of the turbo-molecular pump shown in FIG. 3; FIG. 5A is a horizontal cross-sectional view showing the cross-sectional area of flow passage in a portion around a stator blade and a rotor blade at a first stage of the turbo-molecular pump shown in FIG. 3; FIG. 5B is a perspective view showing a part of the flow passage shown in FIG. 5A; FIG. 6 is an enlarged view showing an essential part of a turbo-molecular pump according to a third embodiment of the present invention; FIG. 7 is an enlarged view showing an essential part of a turbo-molecular pump according to a fourth embodiment of the present invention; FIG. 8 is an enlarged view showing an essential part of a turbo-molecular pump according to a fifth embodiment of the present invention; FIG. 9 is a cross-sectional view of a turbo-molecular pump according to a sixth embodiment of the present invention; FIG. 10 is a cross-sectional view of a turbo-molecular pump according to a seventh embodiment of the present invention; FIG. 11 is a cross-sectional view of a turbo-molecular pump according to an eighth embodiment of the present invention; FIG. 12 is a cross-sectional view of a conventional turbo-molecular pump; FIG. 13A is a plan view of a stator blade shown in FIG. 12; FIG. 13B is a cross-sectional view of the stator blade shown in FIG. 13A; and FIG. 14 is an enlarged view showing a part of the turbo-molecular pump shown in FIG. 12 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, turbo-molecular pumps according to embodiments of the present invention will be described below with reference to FIGS. 1 through 11. Like or corresponding parts are denoted by like or corresponding reference numerals throughout views. Those parts of turbo-molecular pumps according to the present invention which are identical to or correspond to those of the conventional turbo-molecular pump shown in FIGS. 12 through 14 are denoted by identical reference numerals, and will not be described in detail below. FIGS. 1 and 2 show a turbo-molecular pump according to a first embodiment of the present invention. In this embodiment, a turbo-molecular pump has an axial turbine blade pumping section L 1 and a radial turbine blade pumping section L 2 which comprise a turbine blade section, respectively, shown in FIGS. 12 through 14. As shown in FIGS. 1 and 2, the stator blade 38 at the first stage in the radial turbine blade pumping section L 2 has a tapered surface 38 a which is gradually inclined downwardly in a radially inward direction to make the stator blade 38 gradually smaller in thickness so that the gap G between this first-stage stator blade 38 and the rotor blade 30 located immediately above the first-stage stator blade 38 and at the lowermost stage in the axial turbine blade pumping section L 1 is gradually larger toward the inner circumferential side of the stator blade 38 , i.e. the inner circumferential side of the radial turbine blade pumping section L 2 . Other details of the turbo-molecular pump according to the present embodiment are identical to those of the conventional turbo-molecular pump shown in FIGS. 12 through 14. According to the present embodiment, the cross-sectional area of the flow passage defined between the stator blade 38 at the first stage in the radial turbine blade pumping section L 2 and the rotor blade 30 located immediately above this first-stage stator blade 38 and at the lowermost stage in the axial turbine blade pumping section L 1 is prevented from being gradually smaller in the direction of gas flow. Thus, the gas flowing from the axial turbine blade pumping section L 1 to the radial turbine blade pumping section L 2 can be guided smoothly toward the inner circumferential side of the radial turbine blade pumping section L 2 . In this embodiment, the stator blade 38 at the first stage has a thickness which is smaller toward a radially inward direction. However, the stator blade 38 at the first stage has such a shape as to be thinner in a step-like manner so that the gap G between this first-stage stator blade 38 and the rotor blade 30 located at the lowermost stage in the axial turbine blade pumping section L 1 is larger in the step-like manner. It is important that the cross-sectional area of the flow passage per unit length in the direction of gas flow is substantially the same. FIGS. 3 and 4 show a turbo-molecular pump according to a second embodiment of the present invention. In the present embodiment, in the radial turbine blade pumping section L 2 , the outer diameter Dr 1 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the first stage, the outer diameter Dr 2 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the second stage, and the outer diameter Dr n of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at other stages have the relationship of Dr 1 <Dr 2 <Dr n . Further, the inner diameter Ds 1 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the first stage, the inner diameter Ds 2 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the second stage, and the inner diameter Ds n of the stator (outer diameter of the spiral ridge-groove portion) at its portion facing the outer circumferential surface of the rotor blade 36 at other stages have the relationship of Ds 1 >DS 2 >Ds n . Other details of the turbo-molecular pump according to the second embodiment are identical to those of the conventional turbo-molecular pump shown in FIGS. 12 through 14. According to the present embodiment, the cross-sectional area S 1 (see FIG. 5A) of the flow passage F 1 in an axial direction defined between the inner circumferential surface of the stator blade 38 at the first stage in the radial turbine blade pumping section L 2 and the outer circumferential surface of the rotor, and the cross-sectional area S 2 (see FIG. 5A) of the flow passage F 2 in an axial direction defined between the outer circumferential surface of the rotor blade 36 at the first stage in the radial turbine blade pumping section L 2 and the inner circumferential surface of the stator are enlarged for thereby guiding the gas smoothly toward a radial direction in flow passages upstream and downstream of the flow passage F 1 and the flow passage F 2 . Specifically, as shown in FIGS. 4, 5 A and 5 B, if the stator blade 38 has the inner diameter of Dr 0 and the rotor blade 36 has the outer diameter of Ds 0 , then the above cross-sectional areas S 1 and S 2 are expressed by the following formulas: S 1 ={( Dr 0 /2) 2 −( Dr 1 /2) 2 }·π. S 2 ={( Ds 1 /2) 2 −( Ds 0 /2) 2 }·π. On the other hand, in the case where the width of the flow passage defined by the spiral groove at the inner circumferential edge is W i , the width of the flow passage defined by the spiral groove at the outer circumferential edge W 0 , the hight of the flow passage defined by the spiral groove at the inner circumferential edge H i , the hight of the flow passage defined by the spiral groove at the outer circumferential edge H 0 , and the number of ridges J, the cross-sectional area S i of the flow passage at the inner circumferential edge and the cross-sectional area S 0 of the flow passage at the outer circumferential edge are expressed by the following formulas: S i =W i ×H i ×J S 0 =W 0 ×H 0 ×J Therefore, the outer diameter Dr 1 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the first stage and the inner diameter Ds 1 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the first stage are set to such dimensions that the cross-sectional area S 1 of the flow passage F 1 is equal to or larger than the cross-sectional area S i of the flow passage at the inner circumferential side, and the cross-sectional area S 2 of the flow passage F 2 is equal to or larger than the cross-sectional area S 0 of the flow passage at the outer circumferential side. Thus, the stagnation of gas flow in the radial turbine blade pumping section L 2 can be avoided. If the shape of the spiral ridge-groove section on the front surface of the stator blade 38 is different from that on the backside surface of the stator blade 38 , then the cross-sectional area S 1 of the flow passage F 1 is equal to or larger than the larger of the two cross-sectional areas S i at the inner circumferential side. If the shape of the spiral ridge-groove section on the backside surface of the stator blade 38 is different from that on the front surface of the stator blade 38 at the next stage, then the stagnation of the gas flow in the radial turbine blade pumping section L 2 can be avoided by allowing the cross-sectional area S 2 of the flow passage F 2 to be equal to or larger than the larger of the two cross-sectional areas S 0 at the outer circumferential side. According to this embodiment, the outer diameters Dr 1 , Dr 2 and Dr n of the rotor at their portions facing the inner circumferential surfaces of the stator blades 38 in the radial turbine blade pumping section L 2 have the relationship of Dr 1 <Dr 2 <Dr n . However, if the number of stages is n, the following formula should hold: Dr 1 ≦Dr 2 ≦. . . ≦Dr n (on condition that Dr 1 =Dr 2 =. . . =Dr n is excepted therefrom) Further, according to this embodiment, the inner diameters Ds 1 , Ds 2 and Ds n of the stator at their portions facing the outer circumferential surfaces of the rotor blades 36 have the relationship of Ds 1 >Ds 2 >Ds n . However, if the number of stages is n, the following formula should hold: Ds 1 ≧Ds 2 ≧. . . ≧Ds n (on condition that Ds 1 =Ds 2 =. . . =Ds n is excepted therefrom) This relationship holds true for other embodiments of the present invention. FIG. 6 shows a turbo-molecular pump according to a third embodiment of the present invention. According to the third embodiment, in the radial turbine blade pumping section L 2 , the outer diameter Dr 1 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the first stage, the outer diameter Dr 2 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the second stage, and the outer diameter Dr n of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at other stages have the relationship of Dr 1 <Dr 2 <Dr n . Further, the inner diameter Ds of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the first stage in the radial turbine blade pumping section L 2 is set to be equal in all stages. With this arrangement, the cross-sectional area S 1 (see FIG. 5A) of the flow passage F 1 in an axial direction defined between the inner circumferential surface of the stator blade 38 at the first stage in the radial turbine blade pumping section L 2 and the outer circumferential surface of the rotor is enlarged for thereby guiding the gas smoothly toward a radial direction in flow passages upstream and downstream of the flow passage F 1 . FIG. 7 shows a turbo-molecular pump according to a fourth embodiment of the present invention. According to the fourth embodiment, in the radial turbine blade pumping section L 2 , the inner diameter Ds 1 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the first stage, the inner diameter Ds 2 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the second stage, and the inner diameter Ds n of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at other stages have the relationship of Ds 1 >Ds 2 >Ds n . Further, the outer diameter Dr of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the first stage in the radial turbine blade pumping section L 2 is set to be equal in all stages. With this arrangement, the cross-sectional area S 2 of the flow passage F 2 (see FIG. 5A) in an axial direction defined between the outer circumferential surface of the rotor blade 36 at the first stage in the radial turbine blade pumping section L 2 and the inner circumferential surface of the stator is enlarged for thereby guiding the gas smoothly toward a radial direction in flow passages upstream and downstream of the flow passage F 2 . FIG. 8 shows a turbo-molecular pump according to a fifth embodiment of the present invention. The turbo-molecular pump according to the fifth embodiment incorporates the features of the turbo-molecular pump according to the first embodiment and the features of the turbo-molecular pump according to the second embodiment. More specifically, the stator blade 38 at the first stage in the radial turbine blade pumping section L 2 has a tapered surface 38 a which is gradually inclined downwardly in a radially inward direction to make the stator blade 38 gradually smaller in thickness so that the gap G between this first-stage stator blade 38 and the rotor blade 30 located immediately above the first-stage stator blade 38 and at the lowermost stage in the axial turbine blade pumping section L 1 is gradually larger toward the inner circumferential side of the stator blade 38 . Further, in the radial turbine blade pumping section L 2 , the outer diameter Dr 1 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the first stage, the outer diameter Dr 2 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the second stage, and the outer diameter Dr n of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at other stages have the relationship of Dr 1 <Dr 2 <Dr n . Further, the inner diameter Ds 1 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the first stage, the inner diameter Ds 2 of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at the second stage, and the inner diameter Ds n of the stator (outer diameter of the spiral ridge-groove section) at its portion facing the outer circumferential surface of the rotor blade 36 at other stages have the relationship of Ds 1 >Ds 2 >Ds n . With this arrangement, the turbo-molecular pump according to the fifth embodiment can obtain the synergistic effect of the turbo-molecular pumps according to the first and the second embodiments. FIG. 9 shows a turbo-molecular pump according to a sixth embodiment of the present invention. In this embodiment, a turbo-molecular pump has an axial thread groove pumping section L 3 comprising cylindrical thread grooves and a radial turbine blade pumping section L 2 at the upper and lower sides thereof. Specifically, in this turbo-molecular pump, the rotor body 20 has a cylindrical thread groove section 54 having thread grooves 54 a , and the thread groove section 54 and the casing 10 jointly make up the axial thread groove pumping section L 3 for evacuating gas by way of a dragging action of the thread grooves in the rotor R which rotates at a high speed. In the radial turbine blade pumping section L 2 , the stator blade 38 at the first stage has a tapered surface 38 a which is gradually inclined downwardly in a radially inward direction to make the stator blade 38 gradually smaller in thickness. According to this embodiment, the axial thread groove pumping section L 3 comprising the cylindrical thread grooves functions effectively in the pressure range of 1 to 1000 Pa, and hence this turbo-molecular pump can be operated in the viscous flow range close to the atmosphere although the ultimate vacuum is low. FIG. 10 shows a turbo-molecular pump according to a seventh embodiment of the present invention. In the seventh embodiment, a turbo-molecular pump has an axial thread groove pumping section L 3 comprising cylindrical thread grooves between the axial turbine blade pumping section L 1 and the radial turbine blade pumping section L 2 which comprise a turbine blade section. Specifically, the rotor body 20 has a thread groove section 54 having thread grooves 54 a formed in an outer circumferential surface thereof at its intermediate portion, and the thread groove section 54 is surrounded by a thread groove pumping section spacer 56 , thereby constituting the axial thread groove pumping section L 3 for evacuating gas molecules by way of a dragging action of the thread grooves in the rotor R which rotates at a high speed. In the radial turbine blade pumping section L 2 , the outer diameter Dr 1 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the first stage, the outer diameter Dr 2 of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at the second stage, and the outer diameter Dr n of the rotor at its portion facing the inner circumferential surface of the stator blade 38 at other stages have the relationship of Dr 1 <Dr 2 <Dr n . Further, the inner diameter Ds 1 of the stator at its portion facing the outer circumferential surface of the rotor blade 36 at the first stage in the radial turbine blade pumping section L 2 , and the inner diameter Ds n of the stator at its portion facing the outer circumferential surface of the rotor blade 36 at other stages have the relationship of Ds 1 >Ds n . According to this embodiment, three-stage pumping structure is constructed to thus improve pumping speed of the turbo-molecular pump. FIG. 11 shows a turbo-molecular pump according to an eighth embodiment of the present invention. According to the eighth embodiment, a turbo-molecular pump has an axial turbine blade pumping section L 1 and a radial turbine blade pumping section L 2 which comprise a turbine blade section shown in FIGS. 12 through 14. As shown in FIG. 11, the rotor blade 36 at the first stage in the radial turbine blade pumping section L 2 has a tapered surface 36 a which is gradually inclined downwardly in a radially outward direction to make the rotor blade 36 gradually smaller in thickness so that the gap between the first-stage rotor blade 36 and the stator blade 32 located immediately above the first-stage rotor blade 36 and at the lowermost stage in the axial turbine blade pumping section L 1 is gradually larger toward the outer circumferential side of the rotor blade 36 , i.e. the outer circumferential side of the radial turbine blade pumping section L 2 . Other details of the turbo-molecular pump according to the present embodiment are identical to those of the conventional turbo-molecular pump shown in FIGS. 12 through 14. According to the present embodiment, the gas flowing from the axial turbine blade pumping section L 1 to the radial turbine blade pumping section L 2 can be guided smoothly toward the outer circumferential side of the radial turbine blade pumping section L 2 . As described above, according to the above embodiments, the turbo-molecular pumps have the radial turbine blade pumping section, and the axial pumping section comprising turbine blades or thread grooves. However, the principles of the present invention are also applicable to a turbo-molecular pump having only the radial turbine blade pumping section. Further, the combination of the radial turbine blade pumping section and the axial pumping section is not limited to the above embodiments. Furthermore, although the spiral ridge-groove sections are formed in the stator blades of the stator in the embodiments, the spiral ridge-groove sections may be provided on the rotor blades of the rotor, or both of the stator blades of the stator and the rotor blades of the rotor. As described above, according to the present invention, the gas flowing from an axial direction to a radial direction can be smoothly guided, and the stagnation of the gas flow in the radial turbine blade pumping section can be avoided for thereby allowing the gas to flow smoothly and preventing evacuation performance from being lowered. Although certain preferred embodiments of the present invention have been shown and described in detail, it should be understood that various changes and modifications may be made therein without departing from the scope of the appended claims.
A turbo-molecular pump evacuates gas with a rotor that rotates at a high speed. The turbo-molecular pump comprises a casing, a stator fixedly mounted in the casing and having stator blades, a rotor rotatably provided in the casing and having rotor blades alternating with the stator blades, and a radial turbine blade pumping section having a spiral ridge-groove section provided on at least one of surfaces, facing each other, of the stator blade and the rotor blade. At least one of the stator blade and the rotor blade which are located at a first stage of the radial turbine blade pumping section has such a shape that at least one of the stator blade and the rotor blade is smaller in thickness in a direction of gas flow.
5
This invention was made with Government support and the Government has certain rights in the invention. This invention relates to monoclonal antibodies. Recent developments in hybridoma technology have demonstrated that human T cells can be divided into more than one functionally distinct subpopulation. For example, Reinherz et a., Cell, 19:821 (1980) and Reinherz et al., Immunology Today, 4:69 (1981) describe studies which indicate that certain T cell subsets have inducer functions, whereas other subsets have suppressor functions. Other studies have demonstrated that communicative interactions occur between and within the major T cell subsets in the generation of specific effector functions; Evans et al., J. Immunol., 120:1423 (1978); Morimoto et al., J. Immunol., 128:1645 (1982); Thomas et al., J. Immunol., 125:2402 (1980); Gatenby et al., J. Exp. Med., 156:55 (1982); and Yachi et al., J. Immunol., 129:103 (1982). Because regulatory mechanisms are essential to the maintenance of immune homeostasis, an understanding of the interactions between the subsets is of considerable importance. It has been shown that within the major T cell sets, T4 and T8, there exist both functional and phenotypic heterogeneity; Thomas et al., J. Immunol., 125: 2402 (1980); Morimoto et al., J. Immunol., 128: 1645 (1982); Gatenby et al., J. Exp. Med., 156: 55 (1982); and Reinherz et al., J. Immunol., 126: 67 (1981). Interaction between subpopulations of T4 and T8 cells, for example, is required to induce suppression of IgG production in antigen, pokeweed mitogen, or autologous leukocyte reaction-driven systems. Similarly, differentiation of T8 cytotoxic effectors from precytotoxic T8 lymphocytes in mixed leukocyte reactions has been shown to require the presence of T4 cells. A number of monoclonal and autoantibodies have been developed which have provided an initial phenotypic definition of the heterogeneity within the major populations of these cells. Morimoto et al., J. Clin. Invest., 67: 753 (1981) describes using naturally occurring anti-T cell antibodies found in some patients with active juvenile rheumatoid arthritis (JRA) to subdivide T4 cells into helper population (T4JRA-) and an inducer of suppressor subpopulation (T4JRA+) for pokeweed mitogen and antigen driven immunoglobulin production. Similarly, Reinherz et al., J. Immunol., 128: 463 (1982) describes using antibody to Ia to divide T4 cells into T4Ia+ and T4Ia- subsets; both subsets were required to induce optimal Ig secretion by B cells. SUMMARY OF THE INVENTION In general, the invention features a monoclonal antibody and a method of distinguishing subsets within a plurality of human cells, preferably T cells such as T4 cells, which method includes producing a monoclonal antibody to a non-human primate cell such as a marmoset or chimpanzee T cell, contacting the monoclonal antibody with the human cells, and distinguishing the subsets on the basis of different degrees of reactivity with the monoclonal antibody. The antibody is useful in the diagnosis and/or treatment of a disease, e.g., Juvenile Rheumatoid Arthritis (JRA), Sjogren's disease, or Systemic Lupus Erythematosis (SLE), caused or exacerbated by the immunizing subset. Diagnosis could be accomplished using flow cytometry to measure reactivity of cells, with the antibody conjugated with a fluorescent dye. To treat the disease, the antibody could be chemically coupled to a cytotoxic agent and administered to a patient suffering from the disease. The antibody would specifically bind to and destroy the disease-causing cells, but not the normal cells. The method of the invention permits the division of an otherwise apparently homogeneous population (or "set") of human cells into unique subpopulations (or "subsets"), thus making possible diagnosis of such autoimmune diseases as Juvenile Rheumatoid Arthritis (JRA), Sjogren's disease, and Systemic Lupus Erythematosis (SLE), in which T cells are implicated. Immunization of a mammal with a non-human primate cell thus can produce a monoclonal antibody which reacts to a greater degree with a first subset of a set of human cells than with a second subset, even though the two subsets exhibit substantially the same degree of reactivity with a different monoclonal antibody which defines the set; e.g., an antibody highly reactive with T4 cells but exhibiting little reactivity with T8 cells. Preferably the human cells are lymphocytes, e.g., B cells or T cells such as T4 or T8 cells. It has been discovered that an additional benefit is realized by immunization of a mammal with non-human primate cells: for reasons which are as yet unclear, antigenic determinants common to a human and a non-human primate cells sometimes can exhibit greater immunogenicity in rodents, e.g., mice, when presented on the non-human cell, compared to the human cell. This may be because of a comparatively greater immunodominance of some determinants on non-human primate cells, perhaps owing to the expression of the determinant on the non-human cell in a more highly antigenic configuration. This discovery makes possible increased production of monoclonal antibodies against important but weakly antigenic determinants on human cells, by immunizing with a non-human primate cell also bearing the determinant. The method of using non-human primate cells to produce a monoclonal antibody capable of dividing a set of human cells into subsets can be carried out with an additional step, to produce a monoclonal antibody which is specific for one of the subsets, as follows. Once a non-human primate-derived monoclonal antibody has been used to identify two distinct subsets of, say, human T4 cells (one subset being more reactive and the other less reactive with the antibody), one of the identified subsets (say the more reactive subset) can be used to immunize mice and to produce a plurality of hybridomas; the monoclonal antibodies produced by these hybridomas can then be screened against the immunizing subset and the other subset. An antibody more reactive with the immunizing subset than with the other subset defines the polymorphic surface structure or structures which differentiate the two subsets. Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof, and from the claims. DESCRIPTION OF THE PREFERRED EMBODIMENTS The drawings will first be described. DRAWINGS FIG. 1 is a flow chart of an antibody production method, discussed above. FIG. 2 is a set of graphs showing reactivities of an antibody of the invention with human T cells. FIG. 3 is a histogram showing induction of help by various cells and cell combinations. FIG. 4 is a pair of graphs showing the relationship between cells carrying the antigenic determinant of the invention and another antigen. FIG. 5 is an autoradiograph biochemically characterizing the antigenic determinant of the invention. IMMUNIZATION WITH NON-HUMAN PRIMATE CELLS The first step in the method is to select the non-human primate whose cells are to be used for immunization. The choice of primate depends in part on how phylogenetically distant the primate is from humans. This phylogenetic distance is generally reflected in the reactivity of a primate's cells with monoclonal antibodies of human origin. Table 1, below, shows the reactivities of T-cells of various species with monoclonal antibodies produced by immunizing Balb/C or CAFl mice with a variety of human T-cell subsets. Cells of chimpanzees, phylogenetically close to humans, react with all of the human cell-derived antibodies, while cells of the distant lemur react with none. Common marmoset T-cells are reactive with T4A and T8A, but with none of the other antibodies. TABLE 1__________________________________________________________________________SUPPRESSOR/CYTOTOXIC HELPER/INDUCERT CELL DETERMINANTS T CELL DETERMINANTSSpecies T8 T5 T8A T8B T8C T4 T4A T4B T4C__________________________________________________________________________Man 25 ± 4.sup.a 20 ± 1 25 ± 4 25 ± 4 25 ± 4 41 ± 2 41 ± 2 41 ± 2 41 ± 2Chimpan- 51 39 ± 1 46 ± 6 54 ± 4 56 ± 5 27 35 32 31 ± 4zeeGibbon 54 ± 11 40 ± 5 55 ± 10 51 ± 8 51 ± 10 25 ± 1 21 ± 4 19 ± 4 <2Formosan 23 ± 8 20 ± 4 <5 27 ± 8 28 ± 7 28 ± 10 27 ± 10 <2 11 ± 6rockmacaqueOwl <5 26 ± 3 <5 <5 7 ± 2 <2 45 ± 0 43 ± 1 <2MonkeyCommon <5 <5 21 ± 2 <5 <5 <2 42 ± 4 <2 7MarmosetGalago <5 <5 <5 <5 <5 <2 <2 <2 <2Lemur N.T. N.T. N.T. N.T. N.T. <2 <2 <2 <2__________________________________________________________________________ *The data are expressed as the percent PBM staining positive ± S.D. Non-human primate T cells can be used for immunization as follows. First, the cells are isolated from heparinized blood utilizing Ficoll-Hypague and density gradient centrifugation. The cells are then treated with 0.15M NH 4 Cl to lyse erythrocytes, washed, resuspended in phosphate buffered saline, and used for immunization and frozen for subsequent screening. Balb/C or CAFl mice are then immunized with these cells using standard procedures. The splenocytes obtained are fused in PEG with P3/NS1/1-AG4-1 myeloma cells. Hybridoma culture supernatants reactive with immunizing cells, but partially reactive with human T cells or T cell lines, are then selected, and these lines are cloned and recloned by limiting dilution in the presence of feeder cells using standard techniques. The initial screen is meant to identify antibodies reactive with primate T-cells and reactive with some but not all human T lymphocytes. Subsequent screening then involves the characterization of such antibodies on large panels of human T lymphocytes, including freshly isolated T4 cells, T4JRA-TQl+, T4JRA-TQl-, T4JRA+, T8 cells, T4 cytotoxic lines, T8 cytotoxic lines, T4 antigen specific inducer T cell lines, T4 antigen specific inducer of suppressor T cell lines, T8 suppressor lines, and freshly isolated activated T cells. Antibodies which are reactive with a fraction of the inducer or suppressor population but may or may not be unreactive with human B lines B-lymphocytes, mycloid cells and mycloid lines are isolated. Such antibodies can then be used to divide a T4 or T8 population into subsets, based on the degree to which cells from each subset react with the antibodies. Such different reactivities will indicate either the existence of polymorphic epitopes in the structure of a single surface antigen which defines, say, T4 or T8; or the existence of a family of such surface antigens which define the T4 and T8 population, which family of antigens exhibits heterogeneity. In either case, the polymorphism or heterogeneity can be detected using primate-derived monoclonal antibodies. Given the variety of abnormalities in immunoregulatory subsets that exist in a number of autoimmune diseases, the definition of either polymorphic determinants or unique subsets can prove to be very important, given the fact that variations in structures of the MHC complex are of importance in predicting disease susceptibility. Antibodies that react with subfractions of T4 and T8 populations of cells are characterized by indirect immunofluorescence, as follows. Approximately 10 6 cells are incubated with either hybridoma supernatants or ascites, washed at 4° C. extensively, and then stained with FITC anti-mouse IgG. The fluorescent antibody-coated cells are then analyzed on a FACs I, an EPICS V, or a similar instrument, which allow for a precise quantitative assessment of the number of reactive cells. ANTI-4B4 A particular anti-primate cell monoclonal antibody, designated anti-4B4, was produced using standard techniques, as follows. BALB/c J mice (Jackson Laboratories, Bar Harbor, ME) were immunized with cells of a T lymphocyte line derived from the cotton top tamarin Saguinus Oedipus, an herbivorous New World primate species. Peripheral blood lymphocytes from this species were stimulated in vitro with PHA and then maintained in continuous culture with T cell growth factors. Hybridoma cultures containing antibodies reactive with human (E+) cells were selected, cloned, and recloned by limiting dilution methods in the presence of feeder cells; E+ cells are known to be capable of defining T cell specific antibodies from those unreactive with T cells. Malignant ascites were then developed and utilized for analysis. The monoclonal antibody anti-4B4 was shown to be of the IgGl isotype by specificity of staining with fluorescein-labeled goat anti-mouse IgG (Meloy Laboratories, Springfield, VA), and by it failure to be stained by fluorescein-labeled antibodies directed against other subclasses of mouse immunoglobulin. PREPARATION OF T4+ and T8+ CELL SETS Human E+ lymphocytes were treated with anti-T4 or anti-T8 monoclonal antibodies and rabbit complement (C) (Pel-Freeze Biologicals). 2×10 7 cell aliquots were incubated with 1 ml of antibody at a 1:250 dilution for 1 hour at room temperature and then 0.3 ml rabbit C was added to the mixture. The mixture was incubated for another hour in a 37° C. shaking water bath, washed, and residual cells cultured overnight at 37° C. After lysis of cells with anti-T4 and C, >90% of the residual cells were T8+ cells and <5% were T4+ cells. After lysis with anti-T8 and C, >90% of the remaining cells were T4+ cells and <5% were T8+ cells. These two populations will be referred to herein as the T8+ and T4+ sets, respectively. ANALYSIS AND SEPARATION OF LYMPHOCYTE POPULATIONS WITH A FLUORESCENCE-ACTIVATED CELL SORTER Cytofluorographic analysis of cell populations was performed by means of indirect immunofluorescence with fluorescein-conjugated (F(ab') 2 goat anti-mouse (Fab') 2 on an Epics V cell sorter (Coulter Electronics). Background fluorescence reactivity was determined with a control ascites obtained from mice immunized with nonsecreting hybridoma clons. For analysis, all monoclonal antibodies were utilized in antibody excess at dilutions of 1/250 to 1/1000. To separate T4+ T cells into 4B4+ and 4B4-, 80×10 6 T4+ cells, which had been cultured overnight were labeled with 4 ml of a 1/250 dilution of anti-4B4 and developed with fluorescein-conjugated F(ab') 2 goat anti-mouse F(ab') 2 . By using an Epics V cell sorter, the T4+ cells were separated into 4B4+ and 4B4- subpopulations. This procedure produced two subsets of T4+ cells, a subset exhibiting high reactivity with anti-4B4 (designated "4B4+"), and a subset exhibiting low reactivity with anti-4B4 ("4B4-"). Post-sort viability was greater than 95% by trypan blue exclusion in all instances. Purity of separated T cell subsets was in excess of 95%. CHARACTERIZATION OF ANTI-4B4 FIG. 2 is a cytofluorographic analysis of unfractionated T, T4+, and T8+ cells with anti-4B4 monoclonal antibody, displayed in logarithmic scale. As shown in FIG. 2, anti-4B4 was found to be reactive with 41±2% (mean±SE, n=13) of peripheral blood human T lymphocytes and reactive with 41±3% (mean±SE, n=14) of T4+ T lymphocytes and 43±4% (mean±SE, n=10) of T8+ T lymphocytes. Thus, 4B4+ T cells were found in both T4+ and T8+ subpopulations. The reactivity of anti-4B4 antibody with other human lymphoid cells and cell lines is shown in Table 2, below. Anti-4B4 was found to be reactive with over 30% of both peripheral blood null cells, macrophages and thymic lymphocytes, only slightly reactive with peripheral blood B cells. Anti-4B4 was reactive with all 4 human T cell lines tested. The data in Table 2 also indicate reactivity of anti-4B4 with four lymphoblastoid B cell lines and two Burkitt's lymphoma lines. In addition, three hematopoietic cell lines tested, K562, U-937 and KG-1, were anti-4B4 reactive. These results suggest that the reactivity of anti-4B4 is not restricted to cultured cell lines of the T lineage; rather, non-T cells are also anti-4B4 reactive. TABLE 2______________________________________Reactivity of Anti-4B4 Antibodywith Human Lymphoid and Cell Lines.sup.a______________________________________I. Lymphoids cells B cells ± Null cells + M.0. +II. Thymocytes +III. T cell lines HSB + CEM + JM + Molt 4 +IV. B cell Laz 461 + Laz 509 + Laz 388 + Laz 156 + Raj + Daudi +V. Hematopoietic lines U-937 + K562 + KG-1 +______________________________________ .sup.a Reactivity of anti4B4 antibody was determined by indirect immunofluorescence on cytofluorograph (-) indicates 5% reactivity above background control; (±) indicate 5 to 30% reactivity; (+) indicate 30% reactivity. PROLIFERATIVE RESPONSE OF UNFRACTIONATED T4+, T4+4B4+ AND T4+4B4- LYMPHOCYTES The following procedure was carried out to determine whether proliferative activity was restricted to one or another subpopulation of T4 cells, e.g., the 4B4+ or 4B4- subset of T4+ cells. T cells were cultured in RPMI 1640 medium with 10% human AB serum, 200 mM L-glutamine, 25 mM HEPES buffer (Microbiological Associates), 0.5% sodium bicarbonate and 1% penicillin-streptomycin. 10 5 cells per microculture well were tested for proliferative response to an optimal dose of phytohemagglutinin (PHA) (Burroughs-Wellcome Co., Research Triangle Park, NC) and concanavalin A (Con A) (Calbiochem, San Diego, CA). The alloantigen-driven proliferative response was measured concurrently by stimulating with mitomycin C-treated Laz 156, an Epstein-Barr virus-transformed human B lymphoid line. Proliferation to tetanus toxoid (TT) (Massachusetts Department of Public Health Biological Laboratories, Jamaica Plain, MA) and mumps antigen (Microbiological Associates) were tested using 10 ug/ml final concentration and a 1:20 dilution, respectively. Macrophages were added to all lymphocyte populations at a 5% final concentration at the initiation of in vitro cultures. Mitogen-stimulated cultures were pulsed after 4 days with 0.15 uCi of tritiated thymidine ( 3 H-TdR) (1.9 Ci/mM sp. act) (Schwarz-Mann, Orangeburg, NY) per cell well; after a 16 hour incubation, the cells were harvested with a Mash II apparatus (Microbiological Associates) and 3 H-TdR incorporation was measured on a Packard Scintillation Counter (Packard Instrument Co., Downers Grove, IL). Background 3 H-TdR incorporation was obtained by substituting medium for mitogen. Soluble and cell surface alloantigen-driven cultures were pulsed after 5 days with 3 H-TdR for 16 hours, harvested, and counted as above. As shown in Table 3, differences in response to Con A, soluble antigens and autologous antigens were seen in T4+4B4+ and T4+4B4- cell populations. In response to Con A and autologous cell antigens (AMLR), T4+4B4- cells incorporated significantly more 3 H-TdR than did the T4+4B4+ population. In contrast, in response to soluble antigens such as TT and mumps, T4+4B4+ cells incorporated significantly more 3 H-TdR than did the T4+4B4- cell population. These differences between the proliferative response of T4+4B4+ and T4+4B4- populations were significant (P 0.05). They showed that the major proliferative activity in response to soluble antigens is found in T4+4B4+ cell population and the major proliferative activity in response to Con A and autologous cell antigen is found in the T4+4B4- cell population. __________________________________________________________________________Proliferative Responses of Unfractionated T4+ T Cells and T4+ 4B4+ andT4+ 4B4- Subpopulations to Nonspecific Mitogens or AntigenicStimulationProliferative T4+ T Cells Treated withResponse T4+ T Cells Anti-4B4 an G/M FITC T4+ 4B4+ T Cells T4+ 4B4- T Cells__________________________________________________________________________Exp 1Media 875 ± 217.sup.a 497 ± 194 505 ± 196 211 ± 108PHA (0.25 ug/ml) 35847 ± 1018 32338 ± 624 25955 ± 2054 46586 ± 3175Con A (30 ug/ml) 55127 ± 1296 52609 ± 3483 17222 ± 496 47444 ± 2592Con A (60 ug/ml) 57626 ± 1632 51782 ± 1135 24039 ± 1198 63160 ± 1384Tetanus Toxoid 28095 ± 5192 44312 ± 4349 106027 ± 1191 5387 ± 2170Mumps 18853 ± 2008 24822 ± 1955 59405 ± 4355 10342 ± 595Allo E.sup.- 25657 ± 2497 23421 ± 3980 25003 ± 2149 19614 ± 2563Auto E.sup.- 5120 ± 2117 5321 ± 1962 705 ± 142 11753 ± 1399Exp 2Media 643 ± 194 816 ± 254 542 ± 172 426 ± 102PHA (0.25 ug/ml) 73512 ± 2459 61493 ± 3328 47210 ± 3895 70873 ± 4944Con A (30 ug/ml) 65657 ± 4443 67193 ± 2492 16849 ± 1492 67548 ± 3129Con A (60 ug/ml) 83238 ± 3440 76692 ± 4621 31246 ± 2456 105853 ± 5644Tetanus Toxoid 21649 ± 1493 21864 ± 2279 80822 ± 6419 1054 ± 252Mumps 7687 ± 1944 6721 ± 1452 8964 ± 1358 1631 ± 24Allo E.sup.- 33164 ± 1258 42964 ± 3654 31860 ± 1459 291110 ± 18Auto E.sup.- 4050 ± 329 4557 ± 218 2255 ± 872 8916 ± 47__________________________________________________________________________ .sup.a Values are expressed as the mean ± SEM of triplicate samples. PWM-STIMULATED IgG SYNTHESIS BY B CELLS CO-CULTURED WITH T4+4B4+ AND T4+4B4- LYMPHOCYTES In order to determine whether T cell help for B cell immunoglobulin production was restricted to the T4+4B4+ or T4+4B4- T cell subset, unfractionated T4+ T cells or T4+4B4+ and T4+4B4- cells were mixed with autologous B lymphocytes, stimulated with PWM in vitro, and total IgG production was measured after 7 days in culture. Unfractionated and separated populations of lymphocytes were cultured in round-bottomed microtiter culture plates (Falcon) at 37° C. in a humidified atmostphere with 5% CO 2 for 7 days in RPMI 1640 supplemented with 20% heat-inactivated fetal calf serum (Microbiological Associates), 0.5% sodium bicarbonate, 200 mM L-glutamine, 25 mM HEPES and 1% penicillin-streptomycin. To determine the effect of various subsets of the T4 cells on secretion of IgG by autologous plasma cells, various numbers of unfractionated T4+ T cells or purified T4+4B4+ and T4+4B4- T cell subsets were added to 5×10 4 B cells in a volume of 1 ml. To this was added 0.1 ml of pokeweed mitogen (PWM) (Gibco Laboratories, Grand Island Biological Co., Grand Island, NY) at a 1:50 dilution. Macrophages were added to all populations at a 5% final concentration at the initiation of in vitro cultures. On day 7, cultures were terminated, supernatants were harvested, and IgG secretion into the supernatant was determined by solid phase radioimmunoassay (RIA) utilizing a monoclonal antibody directed at the Fc portion of the human gamma heavy chain (anti-Fc) (gifted by Dr. V. Raso, Dana-Farber Cancer Institute). As shown in FIG. 3, neither B cells, unfractionated T4+ T cells, or sorted T4+ subsets secreted IgG when cultured alone. In contrast, when unfractionated T4+ T cells and B cells were mixed together and incubated with PWM, 18400±810 ng of IgG were secreted per milliliter of culture supernatant. Incubation of T4+ T cells with anti-4B4 had no effect on the help these cells provided to B cells. When equal numbers of T4+4B4+ and T4+4B4- cells were added to separate cultures of autologous B cells, the IgG secretion induced by the T4+4B4+ T cell subset was approximately 15 times greater than that obtained with the combination of T4+4B4- and B cells (33000±2100 ng vs. 1700±100 ng). Furthermore, a quantitative comparison of the helper function provided by T4+4B4+ and T4+4B4- T cells for B cell IgG production (Table 4, below) showed that the helper effect of T4+4B4+ T cells was strikingly greater than that of T4+4B4- T cells at any number of T cells and B cells tested. Thus, the majority of helper activity for the antibody production in response to PWM by B cells was found within the T4+4B4+ subset of cells, and the T4+4B4- had minimal helper effect in this interaction. TABLE 4______________________________________Quantitative Comparison of Helper Function Provided byT4+ 4B4+ and T4+ 4B4- T Cells for B cell IgG Production IgG (ng/ml) Exp Exp Exp ExpLymphoid Population 1 2 3 4______________________________________B (5 × 10.sup.4).sup.a .sup. 250.sup.b 600 420 320B (5 × 10.sup.4) + T4+ 4B4+ (5 × 10.sup.3) 6000 3400 2400 17200+ T4+ 4B4+ (1 × 10.sup.4) 5600 4800 3800 20000+ T4+ 4B4+ (2 × 10.sup.4) 16000 14800 5200 32000+ T4+ 4B4+ (4 × 10.sup.4) 16200 15200 10000 324005 (5 × 10.sup.4) + T4+ 4B4- (5 × 10.sup.3) 2480 1680 480 2400+ T4+ 4B4- (1 × 10.sup.4) 2800 2400 1160 2600+ T4+ 4B4- (3 × 10.sup.4) 960 2800 1120 2900+ T4+ 4B4- (5 × 10.sup.4) 300 2200 1160 1800T4+ 4B4+ 300 150 200 150T4+ 4B4- 180 200 150 250______________________________________ .sup.a Figures in parentheses represent the number of lymphocytes of each population added to the culture. .sup.b Values are expressed as mean ng/ml of triplicate samples. SE was always less than 10%. EFFECT OF T4+4B4+ OR T4+4B4- CELLS ON THE GENERATION OF SUPPRESSOR EFFECTOR CELLS The following procedure was carried out to determine whether these T4+4B4+ and T4+4B4- subsets of cells had any effect on the generation of suppressor function. Varying numbers of T4+4B4+ or T4+4B4- cells were added to a constant number of B cells (5×10 4 ) in the presence of PWM. Fractionated T4+4B4+ or T4+4B4- cells (2×10 4 ) were added to these cells. As shown in Table 5 (part A and B), when increasing numbers of T8+ cells were added to T4+4B4- cells and B cells, marked suppression in the IgG production was observed. In contrast, when moderate or low numbers of T8+ cells were added to T4+4B4+ cells and B cells, no or only a slight diminution in IgG production was seen. It should be noted that when excess numbers of T8+ cells (4×10 4 ) were added to T4+4B4+ cells and B cells, a moderate amount of suppression in IgG production was seen. These results indicate that T4+4B4- cells are very efficient in the generation of suppression of IgG production by B cells in the presence of T8+ cells. To demonstrate directly that T4+4B4- cells are necessary for the induction of suppression, varying numbers of T4+4B4+ or T4+4B4- cells were added to a constant number of B cells (5×10 4 ) and T4+2H4- or T4+2H4+ cells (2×10 4 ) and T8+ cells (1×10 4 ) in the presence of PWM. As shown in Table 5 (part C and D), when increasing numbers of T4+4B4- cells were added to a constant number of B cells, T4+4B4+ cells and T8 cells, increasing suppression of IgG production was observed (10000 ng vs 680 ng, 6800 ng vs 3200 ng, 6000 mg vs 810 ng). In contrast, the addition of increasing numbers of T4+4B4+ cells resulted in enhanced IgG production. These results suggest that T4+4B4- cells activate or induce T8+ cells to become suppressor effector cells. TABLE 5__________________________________________________________________________Effect of T4+ 4B4+ or T4+ 4B4- Subsets on theGeneration of Suppressor Effector CellsCell Combination.sup.a Cells Added Exp 1 Exp 2 Exp 3__________________________________________________________________________ T8 Cells AddedA. B + T4+ 4B4+ 0 16000.sup.b 14000 8000 5 × 10.sup.3 14000 (12).sup.c 16000 (0) 7600 (5) 1 × 10.sup.4 10400 (35) 16800 (0) 6400 (20) 2 × 10.sup.4 11000 (31) 12400 (11) 6200 (23) 4 × 10.sup.4 5000 (69) 5600 (60) 1900 (76)B. B + T4+ 4B4- 0 2520 3600 3000 5 × 10.sup.3 720 (71) 2800 (23) 2080 (31) 1 × 10.sup.4 560 (78) 1600 (56) 720 (76) 2 × 10.sup.4 80 (97) 1000 (72) 640 (79) 4 × 10.sup.4 80 (99) 370 (90) 80 (97) T4+ 4B4- addedC. B + T4+ 4B4+ + T8 0 10000 16800 6000 1 + 10.sup.4 4400 (56) 7200 (57) 3000 (50) 2 × 10.sup.4 1400 (86) -- 2720 (55) 4 × 10.sup.4 680 (93) 3200 (81) 810 (87) T4+ 4B4+ addedD. B + T4+ 4B4- + T8 0 120 1600 1120 1 × 10.sup.4 180 (0) 7600 (0) 2000 (0) 2 × 10.sup.4 1020 (0) -- 3400 (0) 4 × 10.sup.4 2800 (0) 16400 (0) 7200 (0)__________________________________________________________________________ .sup.a Varying numbers of T8+ cells (group A, B) or varying numbers of T4 4B4+ or T4+ 4B4- (group C, D) were added to a constant number of B cells (5 × 10.sup.4) and T4+ 4B4+ (2 × 10.sup.4) or T4+ 4B4- (2 × 10.sup.4) cells in the presence of PWM without (group A, B) and with 1 × 10.sup.4 T8+ cells (group C, D). .sup.b Values are expressed as mean ng/ml of triplicate samples. SEM was less than 10%. .sup.c Number in parentheses equal % suppression calculated as the following formula: ##STR1## - THE RELATIONSHIP BETWEEN THE T4+2H4+ AND T4+4B4+ CELL SUBSETS T4+2H4+ lymphocytes proliferate well to Con A stimulation, but poorly to soluble antigen stimulation and provide poor help to B cells for PWM-induced Ig synthesis; T4+2H4- cells proliferate poorly upon stimulation with Con A but well on exposure to soluble antigen and provide a good helper signal for PWM-induced Ig synthesis. Moreover, this antibody defines the subset of T4+ cells which is the inducer of the T8+ suppressor cells. In contrast, T4+4B4+ lymphocytes proliferate poorly upon stimulation with Con A but well on exposure to soluble antigen and provide a good helper signal for PWM-induced Ig synthesis. T4+4B4- cells proliferate well to Con A stimulation and provide poor help to B cells for PWM-induced Ig synthesis. Furthermore, the T4+4B4- lymphocyte population contains the suppressor inducer activity. Thus, functionally, the anti-4B4 antibody reacts the T cell subset which is the reciprocal of that defined by anti-2H4. As shown in FIG. 4, anti-4B4 reacts wtih almost all T4+2H4- cells, and anti-2H4 reacts with almost all T4+4B4- cells. Furthermore, using a double fluorescence staining technique with a 4B4-FITC conjugate and 2H4-phycoerythrin conjugate, it was found that 4B4+2H4+ cells constitute less than 10% of the total T4+ population of cells. Thus, functionally and phenotypically the T4+ cell subset defined by anti-4B4 is reciprocal to that subset defined by anti-2H4. CHARACTERIZATION OF THE ANTIGEN DETECTED BY ANTI-4B4 The following procedures were carried out to label and characterize the cell surface antigen detected by anti-4B4. Splenic T cells were prepared by E-rosetting followed by lysis with anti-B1 antibody, anti-Mo1 antibody and complement. After removal of dead cells or Ficoll-Hypaque gradients, the cells were labelled by a modification of the Lactoperoxidase technique. Labelled cells were lysed for 45 min in 0.5% Triton X-100 in 0.05M Tris HCl/0.4M Nacl/2 mM PMSF/2 mM EDTA/50 mM iodoacetamide. Cell nuclei and other insoluble material was removed by centrifugation at 1000 g for 10 min. Immunoprecipitation cell lysates was performed by centrifuging at 100,000 g for 10 minutes and the supernatant pre-cleared twice with Pansorbin (Calbiochem, La Jolla, CA). The supernatant was then cleared with an irrelevant antibody coupled to Sepharose 4B. The pre-cleared supernatant was mixed with 4B4-Sepharose 4B conjugates and incubated for 4 hours at 4° C. After this, the beads were washed 4 times with cell lysis buffer. Complexes were eluted from the beads by boiling in SDS sample buffer and analyzed by 10% SDS polyacrylamide gel electrophoresis (SDS-PAGE). As shown in FIG. 5, lane 2, when run under non-reducing conditions, the 4B4 antigen consists of two bands between 125-135 KD. By contrast, under reducing conditions the antigen (lane 4) runs as a single broad band of 130-140 KD. The apparent two band structure and slightly faster mobility under non-reducing conditions reflect the effects of glycosylation differences and interchain disulfide bonding. DEPOSIT An essentially pure culture of hybridoma cells producing anti-4B4 antibody has been deposited in the American Type Culture Collection, Rockville, Md., and given ATCC Accession No. HB 8703 dated Jan. 22, 1985. USE The monoclonal antibody of the invention can be labeled with a detectable lable, e.g., a radiolabel by conventional procedures, and provide a quantitative measurement of 4H4+ cells in biological samples or in vivo. Because of its specificity for 4H4+ T-cells, the monoclonal antibody of the invention can be used to detect the presence of these cell types in biological samples. The monoclonal antibody of the invention can be used as a diagnostic aid in characterizing the cell types involved in JRA, SLE, Sjogren's disease and other autoimmune disorders in which T-cells are implicated, and of various lymphomas and leukemias arising from T-cells. In addition, in vivo imaging using radiolabeled monoclonal antibody of the invention can provide a noninvasive means for detecting and localizing these cell types, e.g., tumors of T-cell origin. The 4B4 antibody detects a major subpopulation of T4 cells with immunoregulatory activity. The ability to detect this inducer of help in the T4 population may be important for both diagnosis and treatment of various immunoregulatory disorders. The removal of the inducer of help may be a major aid in the transplantation of a variety of tissues including kidney heart, bone marrow as examples. The residual inducers of suppression, i.e. the 4B4 negative population may allow for the establishment of grafts. Moreover, the therapeutic administration of this antibody either alone or coupled to a radioisotope, drug or toxin may have therapeutic benefit in autoimmune diseases or in patients receiving organ transplants since the mechanism whereby transplants are rejected involves the activation of the immune response. Other embodiments are within the following claims.
A method of distinguishing subsets within a plurality of human cells including producing a monoclonal antibody to a non-human primate cell, contacting the monoclonal antibody with the human cells, and distinguishing the subsets on the basis of different degrees of reactivity with the monoclonal antibody.
2
BACKGROUND OF THE INVENTION Clinical illumination devices, especially those using a multi-lamp fixture, should desirably fill the following conditions: (A) All the lamps can be equally focused on the surface to be illuminated, thereby enhancing the illuminating effect. (B) A horizontal shift or a depth change of the lamp light focus is permitted so that the necessary part of a patient's body lying on the operating table can be well illuminated. (C) The foci of all lamps can be shifted in a well-set condition so that their shift can be clearly traced in changing their horizontal position or depth. (D) The illuminating fixture is not moved above the operating table so that the patient on the table can be protected from secondary infection with microbes originating from dust which naturally collects on or adheres to the lamp case and drops onto the patient's body when the lamp case is moved. (E) The above mentioned well-set condition of the lamp foci is not disturbed even after long use. (F) The illuminating fixture is a simple one which can be readily installed on the ceiling of an existing operating room without any major modification, that is, one with high availability of space. (G) The illuminating fixture is so simple in construction that it can be conveniently maintained, inspected or repaired. Of these conditions, (a) to (d) have been variously filled separately, but in no method or fixture all of the conditions (a) to (d) have been filled at the same time. To the best knowledge of the present inventor, there exists not any method or fixture that can fill all of the conditions (a) to (g). SUMMARY OF THE INVENTION The present invention has been accomplished through the inventor's strenuous efforts in experimental studies to meet all the above requirements in one illumination device. The main object of the present invention is to provide a multi-lamp clinical illumination device, whereby a well-set focal condition is not disturbed during long use and such well-set focal condition can be shifted horizontally or vertically over an operating table and the like. Another object of the present invention is to provide a clinical illumination device, whereby the illuminating fixture is not moved through the room but shifted within a limited space, thereby preventing dust from dropping onto the operating table. Still another object of the present invention is to provide a clinical illumination device, whereby the illuminating fixture gives high availability of space; is simplified in construction; and is extremely convenient for maintenance, inspection or repair. To attain these objects of the present invention, a plurality of lamps appropriately arranged on the lamp fixture in the same plane are equally focused to a desired depth. Each lamp at an angle with the focus thus well set is angle-adjustably and extendably attached to a driver fitted to a plane parallel to the lamp-fitting plane. The horizontal direction or depth of the lamp focus can be desirably changed by shifting either the driver or the lamp fixture in a desired horizontal or vertical direction. BRIEF DESCRIPTION OF THE DRAWINGS The clinical illumination device according to the present invention will become apparent by reading the following detailed description of its preferred embodiments with reference to the attached drawings, in which: FIGS. 1 to 4 are schematic views illustrating the working principle of the present invention, FIG. 1 being an elevation view of a two-lamp fixture, and FIGS. 2 to 4 being respectively a plan view, an elevation view and a right side view of a six-lamp fixture. FIG. 5 illustrates a lamp assembly according to the described principle of the present invention. FIGS. 6 to 9 are partially cutaway perspective views of several embodiments of the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Prior to a description of preferred embodiments of the present invention, its working principle will be described with reference to FIGS. 1 through 4. In FIG. 1, the tilting axes O 1 and O 2 of the lamps L 1 and L 2 are positioned in the plane P 1 . An extendable crank K is provided to tilt the lamps L 1 and L 2 , the crank-driving points being set at G 1 , G 2 , G 3 , G 4 , . . . G n , G 2 ', G 4 ' . . . G n '. The planes containing the driving point groups G and G' are designated respectively Q and Q'. All of the planes Q, Q', P 2 , P 2 ' are parallel to one another. The plane P 1 , and the tilting axes O 1 , O 2 contained therein are immovable. The light axes of the lamps L 1 , and L 2 are in perfect alignment with O 1 F 1 and O 2 F 1 , i.e., extensions of the lines O 1 G 1 and O 2 G 3 , while O 1 F 1 and O 2 F 1 meet together at the focus F 1 . Then the driving points of the crank K are located at G 1 and G 3 . As the driving points move from G to G 1 → G 2 → G 2 ' or to G 3 → G 4 → G 4 ', correspondingly the focus shifts from F to F 1 → F 2 → F 2 '. However, the driving points G 1 and G 3 corresponding to the focus F 1 are always interlocked on the planes Q and Q' parallel to the plane P 1 , moving together in the same direction at the same speed. These are the preset conditions. Now between ΔO 1 G 1 G 2 , ΔO 2 G 3 G 4 , ΔO 1 F 1 F 2 and ΔO 2 F 1 F 2 , the following relations hold; ΔO.sub.1 G.sub.1 G.sub.2 ΔO.sub.1 F.sub.1 F.sub.2 Δo.sub.2 g.sub.3 g.sub.4 Δo.sub.2 f.sub.1 f.sub.2 and ΔO.sub.1 G.sub.1 G.sub.2 =ΔO.sub.2 G.sub.3 G.sub.4 from the present condition of G 1 G 2 = G 3 G 4 , line F.sub.1 F.sub.2 in ΔO.sub.1 F.sub.1 F.sub.2 = line F.sub.1 F.sub.2 in ΔO.sub.2 F.sub.1 F.sub.2 and these two lines perfectly overlap each other. Meanwhile, since the ratio of G 1 G 2 :F 1 F 2 and the ratio of G 3 G 4 :F 1 F 2 are the same and constant, the two lines O 1 F 2 and O 2 F 2 meet together at a position Fn corresponding F 2 , regardless of the distance and direction of G 1 G 2 and G 3 G 4 . Next, between ΔO 1 G 2 G 2 ', ΔO 1 F 2 F 2 ', ΔO 2 G 4 G 4 ' and ΔO 2 F 2 F 2 ', the following relations hold: ΔO.sub.1 G.sub.2 G.sub.2 ' ΔO.sub.1 F.sub.2 F.sub.2 ' and ΔO.sub.2 G.sub.4 G.sub.4 ' ΔO.sub.2 F.sub.2 F.sub.2 ' thus, in the former G.sub.2 G.sub.2 ' :F.sub.2 F.sub.2 ' = (distance P.sub.1 Q' ):(distance P.sub.1 P.sub.2 ' ) and in the latter G.sub.4 G.sub.4 ' :F.sub.2 F.sub.2 ' = (distance P.sub.1 Q' ):(distance P.sub.1 P.sub.2 ' ) therefore line F 2 F 2 ' in ΔO 2 F 2 F 2 ' = line F 2 F 2 ' in ΔO 1 F 2 F 2 ', and the two lines are in perfect agreement. Now the necessary and sufficient conditions for the focus F 1 to shift to F 2 and F 2 ' which are arbitrary points are: on the planes Q and Q', G 1 G 2 = G 3 G 4 and G 2 G 2 ' = G 4 G 4 '. This means that G 1 → G 2 → G 2 ' and G 3 → G 4 → G 4 ' be interlocked to take place at the same time in the same direction at the same speed, while the driving points G 1 and G 3 be shifted respectively as G 1 → G 2 → G 2 ' and G 3 → G 4 → G 4 '. This principle will be three-dimensionally valid as shown in FIGS. 2 to 4, even if the structure in FIG. 1 is three-dimensionalized and set up on a longitudinal plane. In the figures LS represents the illuminating fixture. Also it is self-evident that the same principle holds, even if the driving points G 1 , G 3 on the plane Q in FIG. 1 are fixed and the tilting axes O 1 , O 2 on the plane P 1 are movable on the plane P 1 longitudinally, transversely or vertically. Next an embodiment of the present invention based on this principle is illustrated in FIG. 5, where there is no limitation to the number of lamps to be used and the structure of the lamp is the same. Thus, a cylindrical lamp housing 2 is fitted on the plane P 1 below the front board 1 of the lamp assembly in a stationary illuminating fixture, freely tiltable in the longitudinal and the vertical direction in such a manner that the center O of the lamp L may fall within the plane P 1 which is parallel to the front board 1. At the bottom of the lamp housing 2 an infrared absorption filter 3 is provided, while at the top of it a reflector 4 is provided to pass the infrared rays in the light of the lamp L and reflect the visible rays back to the bottom. The lamp housing 2 is tiltable around a tilting axis 6 pivotally connected to the lamp housing holder 5 fixed to the front board 1, and around the tilting axis 8 which pivots the lamp housing 2 and a tilting ring 7 located at 90° to tilting axis 6 on the same plane. To the top of the lamp housing 2 which lies in the central light axis of the lamp L is fixed, via the arm 10, one end of the spring 9, the other end of which is rotatably fitted via the ball joint 12 to the driving rod 11, i.e., the driver for longitudinal (Y-direction) and transverse (X-direction) movement on a plane parallel to the plane P 1 and for vertical (Z-direction) movement relative to the plane P 1 . The movement in the X-direction, the Y-direction and the Z-direction of this driving rod 11 is accomplished according to the above principle, and it makes no difference whether this movement is automatic or manual. At the bottom of the lamp housing holder 5 is fitted a semispherically-shaped transparent globe 14 by means of the globe holder 15 using a packing 13, thereby maintaining air tightness between the top and bottom of the front board. The center O of the lamp L is located on the plane P 1 which is below the front board 1 for the purpose of keeping the illuminating light axis invariable with no decrease in the illuminating efficiency by preventing the effective range of the illuminating light flux from being reduced by the front board 1 or the globe holder 15, even when the angle of the illuminating light axis of the lamp L is substantially changed. Comparing the lamp structure with the above-described principle illustrated in FIG. 1, the center O of the lamp L corresponds to O of the principle, the center of the ball joint 12 corresponds to G of the principle and the spring 9 corresponds to K of the principle. Regardless of the direction in which the driving rod 11 moves, the center of the ball joint 12 and the center O of the lamp L are always aligned. In the figures, 16 is a cord connecting the lamp L to the power supply. Various embodiments of the present invention using the above-mentioned lamp structure are to be illustrated in the following, where like symbols designate like elements. EXAMPLE 1 (FIG. 6) (A plurality of linear lamp groups arranged parallel in two rows) The front board 1 of a rectangular case 17 of the illuminating fixture buried in the ceiling is equipped with two parallel rows of a plurality of lamp housings 2 of the same structure as shown in FIG. 5, fitted by means of the lamp housing holder 5. To the arm 10 of each lamp housing 2 is fitted one end of a spring 9, the other end of which is connected to one of a pair of driving rods 11 provided on a plane parallel to the front board 1, inclined at such an angle that the light axis of each lamp L may converge at a position below an arbitrary illuminating focus, using a ball joint 12 for each row. On an H-shaped X-axis slide base 28 which is slidable in the X-axis direction along guide rails 27 provided at the four corners of the front board 1 is provided a Y-axis slide base 18 which is slidable in the Y-axis direction along the guide rails 28a. Both sides of each driving rod 11 are bent downwardly at 90°. The bottom ends of each rod has screw gears engaged with screw gears in the axial center of bevel gears 20 rotatably fitted to the tops of pipes 19 fixed to the four corners of an H-shaped Y-axis slide base 18, so that they can be raised or lowered within the pipes 19 and the rotating bevel gears 20, thereby displacing the driving rods 11 in the Z-axis direction. Each bevel gear 20 is rotated by another bevel gear 20a which is driven by a Z-axis drive motor 21 installed on the Y-axis slide base 18, via the drive gear 22, the transmission shafts 23, 24, 25, and the bevel gears 26, 26a installed respectively on the Y-axis slide base 18. Y-axis slide base 18 is made to slide in the Y-axis direction by the rotation of the Y-axis drive motor 29 installed at the center of the front board 1, via the male screw 30 fitted to the rotating shaft of motor 29 and via the female screw 31 engaging the male screw 30 and fixed to the Y-axis slide base 18. X-axis slide base 28 is made to slide in the X-axis direction by the rotation of the X-axis drive motor 32 installed at the end of the front board 1, via the male screw 33 fitted to the rotating shaft of motor 32 and via the screw hole bored into the slide wall of the X-axis slide base 28, male screw 33 fitting into the screw hole. In the figure, 34 are connecting plates between the driving rods 11. Thus in this embodiment for the purpose of shifting the illuminating focus F in the X-axis direction, the X-axis drive motor 32 is turned in forward or reverse directions to cause the X-axis slide base 28 to slide in the X-axis direction. Then the illuminating focus F formed by the light axis of the lamp L in each lamp housing 2 connected to one of the driving rods 11 is also shifted along the X-axis on the plane containing focus F. For the purpose of causing the focus F to shift in the Y-axis direction, the Y-axis drive motor 29 is turned in the forward or reverse directions to make the Y-axis slide base 18 slide in the Y-axis direction. Then the focus F also is moved along the Y-axis on the plane containing focus F. For the purpose of causing the focus F to shift in the Z-axis direction, the Z-axis drive motor 21 is turned in the forward or reverse directions to make the driving rods 11 raise or lower. Then the focus will be moved in the Z-axis direction containing focus F. And as explained in the description of the principle illustrated in FIG. 1, the shifting of the focus F can be done without disturbing the focus formed by the light axis of each lamp, that is, without scattering the light field. EXAMPLE 2 (FIG. 7) (A plurality of linear lamp groups arranged in a cruciform) To the front board 36 of a cruciform case 35 of the illuminating fixture buried in the ceiling are attached in a cruciform fashion by means of the lamp housing holders 5 a plurality of lamp housings 2 of the same structure as shown in FIG. 5. To the arm 10 of each lamp housing 2 is fitted one end of a spring 9, the other end of which is connected by means of a ball joint 12 to the cruciform driving rod 37 installed on a plane parallel to the front board 36, at such an angle that the light axis of each lamp L may converge at an arbitrary illuminating focus F. Each end of the driving rod 37 is bent downwardly at 90°. Each bottom end of rod 37 has screw gears engaged with screw gears in the axial center of a bevel gear 40 which is rotatably fitted to the top of the pipe 39 fixed to each end of the Y-axis slide base 38 made of a cruciform board. Rotation of bevel gears 40 causes the driving rod 37 to be raised or lowered within the pipes 39, thereby shifting rod 37 in the Z-axis direction. The Y-axis slide base 38 has an adequate space left at mid-width of the cruciform board which constitutes such base, so that when base 38 is moved, this movement may not be hindered by the lamp housing holders 5. Each bevel gear 40 is rotated by another bevel gear 40a which is rotated by the Z-axis drive motor 41 installed on the Y-axis slide base 38 via the bevel gears 42-46, and the transmission shafts 48-52 respectively provided on the Y-axis slide base 38. On the X-axis slide base 54 which is slidable in the X-axis direction along the guide rails 53 provided at each end of the front board 36 is fitted the Y-axis slide base 38 so that it can slide in the Y-axis direction along the guide rails 54a. Y-axis slide base 38 is made to slide in the Y-axis direction by the rotation of the Y-axis drive motor 55 installed at one corner of the X-axis slide base 54 in the Y-axis direction, via the male screw 56 fitted to the rotating shaft of motor 55 and via the female screw 57 matching male screw 56 and fixed to the Y-axis slide base 38. X-axis slide base 54 is made to slide in the X-axis direction by the rotation of the X-axis drive motor 58 installed at one end of the front board 36, via the male screw 59 fitted to the rotating shaft of motor 58 and via the female screw 60 matching male screw 59 and fixed to one side wall of the X-axis slide base 54 in the X-axis direction. Therefore, for the purpose of shifting the illuminating focus F in the directions of X-, Y- and Z-axes containing focus F, respectively the X-axis drive motor 58, the Y-axis drive motor 55 and the Z-axis drive motor 41 have only to be turned in the forward or reverse directions, the other actions being the same as in Example 1. EXAMPLE 3 (FIG. 8) (A plurality of lamps arranged in a ring) To the front board 62 of a ring case 61 of the illuminating fixture buried in the ceiling are attached in a ring formation by means of the lamp housing holders 5 a plurality of lamp housings 2 of the same structure as shown in FIG. 5. To the arm 10 of each lamp housing 2 is fitted one end of a spring 9, the other end of which is connected via a ball joint 12 to a ring-shaped driving rod 63 provided on a plane parallel to the front board 62, at such an angle that the light axis of each lamp L may converge at an arbitrary illuminating focus F. At an appropriate position of the driving rod 63 are fitted several transmission shafts 64 which extend perpendicularly downwardly. The lower ends of each transmission shaft 64 has screw gears engaged with screw gears in the axial center of the worm wheel 67 fitted rotatably to the top of the pipe 66 fixed to the X-axis slide base 65 made of a ring-shaped board, and the rotation of worm wheels 67 causes the transmission shafts 64 to be raised or lowered within the pipes 66, thereby shifting rod 63 in the Z-axis direction. The X-axis slide base 65 has an adequate space left at mid-width of the ring board constituting such base, so that the movement of the base may not be hindered by the lamp housing holders 5. Each worm wheel 67 is rotated by a worm 70 meshing with the worm wheel 67 through the transmission shaft 69, when worm 70 is driven by the Z-axis drive motor 68 installed on the X-axis slide base 65. The transmission shaft 69, which is formed in a ring of shafts appropriately connected together by universal joints 71, is fitted to the X-axis slide base 65. Guide rails 72 are formed on the peripheral parts of the front board 62 at the intersections of the X-axis and the Y-axis passing through the ring of the front board 62. To guide rails 72 is fitted the Y-axis slide base 73 which is slidable in the Y-axis direction. To the guide rail 73a formed on the Y-axis slide base 73 is fitted X-axis slide base 65 which is slidable in the X-axis direction. Y-axis slide base 73 is made to slide in the Y-axis direction by the rotation of the Y-axis drive motor 74 installed on the peripheral part of the front board 62 where the front board 62 and the Y-axis intersect, via the male screw 75 fitted to the rotating shaft of motor 74 and via the female screw 76 matching the male screw 75 and fixed to the Y-axis slide base 73. X-axis slide base 65 is made to slide in the X-axis direction by the rotation of the X-axis drive motor 77 installed on the Y-axis slide base 73 where the front board 62 and the X-axis intersect, via the male screw 78 fitted to the rotating shaft of motor 77 and via the female screw 79 matching male screw 78 and fixed to the X-axis slide base 65. Thus in this embodiment the shifting of the focus F in the directions of the X-, Y- and Z-axes containing focus F can be done by forward or reverse turning of respectively the X-axis drive motor 77, the Y-axis drive motor 74 and the Z-axis drive motor 68, the other actions being the same as in Example 1. EXAMPLE 4 (FIG. 9) (A plurality of lamps irregularly arranged) To the front board 81 of a polygonal case 80 of the illuminating fixture buried in the ceiling are fitted in a desired irregular array by means of the lamp housing holders 5 a plurality of lamp housings 2 of the same structure as shown in FIG. 5. To the arm 10 of each lamp housing 2 is fitted one end of a spring 9, the other end of which is fitted by means of a ball joint 12 to an irregularly-formed driving rod 82 provided on a plane parallel to the front board 81, at such an angle that the light axis of each lamp L may converge at an arbitrary focus F. Opposite ends of rod 82, in both the X- and Y- axis directions passing the center of the driving rod 82, are bent downwardly at 90°. The lower part of each bent end has screw gears engaged with screw gears in the axial center of the worm wheel 85 rotatably fitted to the top of the pipe 84 fixed to the Y-axis slide base 83 in the same ring form as the front board 81, and the rotation of worm wheels 85 causes the driving rod 82 to be raised or lowered within the pipes 84, thereby shifting rod 82 in the Z-axis direction. Each worm wheel 85 is rotated by a worm 88 meshing with the worm wheel 85 via the transmission shaft 87, when worm 88 is driven by the Z-axis drive motor 86 installed on the Y-axis slide base 83. The transmission shaft 87, which is formed in a ring of shafts appropriately connected together by universal joints 89, is attached to the Y-axis slide base 83. Guide rails 90 are formed at each end of the front board 81 which is intersected by the X-axis and the Y-axis passing through the center of polygonal ring front board 81. To the guide rails 90 is fitted the X-axis slide base 91 which is slidable in the X-axis direction, while to the Y-axis sliding guide rails 91a formed on the X-axis slide base 91 is fitted Y-axis slide base 83 which is slidable in the Y-axis direction. X-axis slide base 91 is made to slide in the X-axis direction by the rotation of the X-axis drive motor 92 installed outside the front board 81 where the front board 81 and the X-axis intersect, via the male screw 93 fitted to the rotating shaft of motor 92 and via the female screw 94 matching male screw 93 and fixed to the X-axis slide base 91. Y-axis slide base 83 is made to slide in the Y-axis direction by the rotation of the Y-axis drive motor 95 installed on the X-axis slide base 91 where the front board 81 and the Y-axis intersect, via the male screw 96 fitted to the rotating shaft of motor 95 and via the female screw 97 matching male screw 96 and fixed to the Y-axis slide base 83. Thus, in this embodiment the shifting of the focus F in the directions of the X-, Y- and Z-axes containing the focus F can be done by forward or reverse turning of respectively the X-axis drive motor 92, the Y-axis drive motor 95 and the Z-axis drive motor 86, the other actions being the same as in Example 1. Whereas in the embodiments illustrated above the angle of the light axis in a number of lamps fixed in position is changed by moving the driving rod in the directions of the X-, Y- and Z-axes, it is obvious that the same effect of changing the focus as in such embodiments may be attained by moving the lamps in the directions of the X-, Y- and Z-axes with the driving rod fixed in position. Also, the driving rod, which is illustrated as a rod, may be a single plate of appropriate size. Many lamps illustrated in the above are all located on the same horizontal plane, but the plane upon which to arrange the lamps may be a curved one or a bent one. It is self-evident that the plane may be modified in any shape or structure, so long as the above principle is satisfied. Using the illuminating fixture illustrated in the above examples, the foci of all lamps in well-set condition can be changed to any horizontal direction and depth of the surface to be illuminated of an operating table by merely switching on or off the drive motors for the X-, Y- and Z-axes without touching any lamp case or other illuminating device. The illuminating fixture of the present invention can be provided within a narrow space of the ceiling above the operating table without making any major modification of the room. Since the illuminating fixture is moved within the ceiling space instead of through the room, there is no possibility of the dust collecting on or adhering to the fixture falling on the operating table. Besides, the illuminating fixture of the present invention, which gives high availability of space, permits an increased number of lamps to be provided, thereby assuring the desired luminous intensity. Moreover, when the driver and the lamp assembly are connected by an elastic material such as a spring, the illuminating fixture can be free from the adverse effect of external vibration or from aging through long use; can perform all the time as it should; can have the lamp angle conveniently varied to facilitate lamp replacement or repair of the light source; and can permit the lamp to revert to its original position by merely releasing it from the hand after the work is finished. Thus it is extremely convenient for maintenance, inspection and repair.
The present invention relates to an apparatus for clinical illumination of an operating room with a number of lamps, which are equally focused on the affected part of a patient's body, characterized in that the horizontal direction on the depth of the light focus from each lamp can be desirably changed by a single manipulation of a simple mechanism without scattering the light from each lamp.
5
CROSS-REFERENCES TO RELATED APPLICATIONS This application claims the benefit of three Provisional Patent Applications: (1) Ser. No. 60/373,497, filed Apr. 17, 2002; (2) Ser. No. 60/386,173, filed Jun. 4, 2002; and (3) Ser. No. 60/426,917, filed Nov. 15, 2002, all entitled “Self-Sealing Retractable Writing Instrument,” which are all incorporated by reference. BACKGROUND OF THE INVENTION Field of the Invention This invention relates to writing instruments, and more particularly to writing instruments that dispense volatile inks, such as felt tip markers and the like. DESCRIPTION OF RELATED ART This invention relates to ink impregnated marking and writing instruments, commonly known as “markers.” The term “markers” as used herein generally includes all such writing instruments where ink may have a tendency to evaporate from its tip. Some examples of markers include, but not limited to, felt-tipped pens, dry erase, permanent and non-permanent markers, and children's markers. Markers have at least one end with a writing tip for writing onto a surface. The writing tip is also referred to as a nib. The ink formulations typically comprise dye and solvent in which the dye is dissolved. These ink solvents are typically volatile, being prone to evaporation when exposed to ambient air. If a sufficient amount of the ink solvent evaporates from the writing tip of the marker, the writing tip dries out, and the performance of the marker substantially degrades. The problem with ink evaporating from the tip is solved by placing a cap over the tip when the marker is not in use. One of the problems with the cap is that the cap is often not put back on the tip after its use because users sometimes forget to put the cap back on or it is misplaced, and without the cap, the tip dries out to shorten the life of the marker. To overcome the problem of having a cap for the marker, some markers are designed with a self-sealing cap integrated into the maker housing. These markers have their own problems in that the self-sealing cap designs are complex and do not work very well. One of the problems is that the writing tip is typically isolated in a relatively large air chamber when the writing instrument is not in use. With a large air chamber, a large amount of ink can still evaporate into the air chamber. Another problem is that as the tip moves in and out of the self-sealing cap there is friction between the self-sealing cap and the tip that can cause the self-sealing cap to deteriorate over time. In addition, the assembly of self-sealing caps is complex so that they may be unsuitable for high volume manufacturing processes. Therefore, there is a need for an improved self-sealing writing instrument. SUMMARY OF THE INVENTION This invention provides a retractable writing instrument that substantially prevents writing fluid from evaporating through the tip when the tip is in a retracted position. The retractable writing instrument includes a front barrel with a front opening to allow the tip to move in and out of the opening. Adjacent to the front opening and within the front barrel is an enclosure member that substantially seals the tip from outside air when the tip is in a retracted position. The writing instrument also includes a back barrel with a back opening. Disposed within the back opening is a plunger that is adapted to move back and forth axially. When the plunger is activated by clicking on it, for example, the tip may be moved in and out of the enclosure member and front opening. Writing fluid is stored in a feeder. A nib is between the feeder and the tip to convey the writing fluid in the feeder to the tip. The nib may be unitary with the tip or may be a separate component. At least a portion of the feeder may extend into the back opening and into the plunger to lengthen the size of the feeder to store more writing fluid. The enclosure member includes a first end and a second end, where the first end is adapted to open to allow the tip to extend through the first end. To open, the first end may have a lip with a slit. To further assist in substantially sealing the lip in the retracted position, a clip may be provided to add compression force to the lip. The second end may have an inner configuration adapted to substantially seal the second end of the enclosure member yet allow the tip to move axially in and out when activated by the plunger. In the retracted position, the tip is between the first and second ends to substantially seal the tip from the ambient air, thereby eliminating the need for a cap. The enclosure member may be made of a material that is durable so that the lip does not wear out after many cycles of moving the tip in and out of the enclosure member. The material should be also impermeable vapor to seal the tip from the ambient air. In this regard, the enclosure member may be made of thermoplastic vulcanizate (TPV) material including butyl rubber cross-linked with polypropylene. Other systems, methods, features, and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims. BRIEF DESCRIPTION OF THE DRAWINGS The invention can be better understood with reference to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. FIG. 1 illustrates a side view of a writing instrument with the tip in a protracted position. FIG. 2 illustrates a side view of the writing instrument with the tip in a retracted position. FIG. 3 illustrates a writing instrument that is disassembled. FIG. 4 is a cross-sectional view of the writing instrument in a retracted position. FIG. 5 is a cross-sectional view of the writing instrument in a protracted position. FIG. 6 is a front perspective view of an enclosure member. FIG. 7 is a rear perspective view of the enclosure member. FIG. 8 is a cross-sectional view of the writing side of the writing instrument. FIG. 9 is cross-sectional view of an alternative writing side of a writing instrument. FIG. 10 is a front perspective view of a clip. FIG. 11 is a rear perspective view of the clip. FIG. 12 is a perspective view of an alternative clip and enclosure member combination. FIG. 13 is a rear perspective view of the enclosure member of FIG. 12 . FIG. 14 is another perspective view of the clip of FIG. 12 . FIG. 15 is a perspective view of another clip and enclosure combination in a retracted position. FIG. 16 is another perspective view of the clip and enclosure combination of FIG. 15 transitioning from the retracted position to the protracted position. FIG. 17 is another perspective view of the clip and enclosure combination of FIG. 15 in the protracted position. FIG. 18 is a perspective view of an alternative writing instrument that is disassembled. FIG. 19 is a cross-sectional view of a cartridge with an elongated portion. FIG. 20 is a front view of the opening in the elongated portion of FIG. 19 . FIG. 21 is a side view of the tip and nib. DETAILED DESCRIPTION FIG. 1 illustrates a writing instrument 100 in a protracted position. The writing instrument 100 has a housing 101 comprised of a first barrel 104 and a second barrel 108 . In the protracted position, a tip 102 of the writing instrument 100 extends from the first barrel 104 . The first barrel 104 has a first opening 106 at the front side to allow the tip 102 to move between the protracted position and the retracted position. The second barrel 108 has a second opening 110 at the back end to allow a plunger 112 to extend between the protracted position and the retracted position. In the protracted position, the plunger 112 is pressed down relative to the second barrel 108 , which causes the tip 102 to extend through the first opening 106 and extend from the first barrel 104 . A support member 115 may wrap around the side of the tip 102 in order to guide the tip 102 through the first opening 106 . The first barrel 104 may reduce the diameter of the housing towards the tip 102 to form the first opening 106 . FIG. 2 illustrates the writing instrument 100 in a retracted position where the tip 102 is inside the first barrel 104 . In the retracted position, the plunger 112 further extends from the second barrel 108 that causes the tip 102 to retract into the first barrel 104 by moving back into the first opening 106 . As such, activating the plunger 112 between the retracted and protracted positions causes the tip 102 to move correspondingly between the retracted and protracted positions as well. The housing 101 may be made of a unitary member as well, where the internal mechanism for the writing instrument 100 are inserted into the housing 101 through the second opening 110 , or through any other alternative mechanism known to one skilled in the art. FIG. 3 is an exploded view of the interior mechanism of the writing instrument 100 . The writing instrument 100 includes an enclosure member 300 adapted to fit within the first barrel 104 adjacent to the first opening 106 . The enclosure member 300 has a first end 302 and a second end 304 forming a vapor chamber within the enclosure member 300 . The vapor chamber is configured to receive the tip 102 to substantially seal the tip 102 from the ambient air. In the protracted position, the first end 302 of the enclosure member 300 opens to allow the tip 102 to extend through the first opening 106 . In the retracted position, the first end 302 closes to substantially seal the tip from the ambient air. The tip 102 may be coupled to a nib 308 along the longitudinal axis 310 . The tip 102 may be a separate component from the nib 308 or a unitary piece. The writing instrument 100 may include a clip 301 to aid in closing the first end 302 of the enclosure member 300 . The clip 300 may be preloaded to apply compressive force on the first end 302 . The enclosure member 300 may be configured so that the clip 301 may couple to the enclosure member 300 on its outer surface. In this way, the clip 301 may be disposed between the enclosing member 300 and the first barrel 104 and encircle the circumference of the second end 304 of the enclosing member 300 . In addition, the second end 304 of the enclosure member 300 may have cutouts for the clip 301 so that the outer circumference of the enclosure member and the clip may combine to form the surface that contacts the inner wall of the housing 101 . The writing instrument 100 may also include a first cartridge 312 adapted to couple to a second cartridge 314 . The first and second cartridges 312 and 314 are adapted to enclose a feeder 316 . The feeder 316 is adapted to store writing fluid that conveys through the nib 308 and then to the tip 102 . The capillary relationship among the feeder 316 , nib 308 , and tip 102 causes the writing fluid to convey from the feeder 316 to the tip 102 . The first cartridge 312 may have an elongated portion 318 with an opening 320 adapted to receive and seal the nib 308 or tip 102 . This allows the back tip 322 of the nib 308 to make contact with the feeder 316 to convey the writing fluid to the tip 102 . The first cartridge 312 has a back flange 327 adapted to associate with a second cartridge member 314 . The back flange 327 may have at least one tab 324 that is adapted to associate with a corresponding channel formed in the second barrel 108 so that the first cartridge 312 moves between the retracted and protracted positions without rotating. This may be done to ensure that the first cartridge moves along the axial direction 310 consistently. The elongate portion 318 of the first cartridge 312 may be inserted into the resisting member 326 such that the resisting member 326 is positioned between the second end 304 of the enclosing member 300 and the edge 325 of the first cartridge 312 . The writing instrument 100 may include a gear 328 that works with the plunger 112 and the second barrel 108 to lock the plunger 112 in the retracted position or the protracted position. The gear 328 is hollow to allow the back end of the second cartridge 314 to pass through the gear 328 . The plunger 112 has a bore 114 that is adapted to receive at least a portion of the feeder 316 held within the second cartridge 314 . Incorporating the feeder 316 inside the plunger 112 extends the length of the feeder 316 to store more writing fluid. FIG. 4 illustrates the cross-sectional view of the writing instrument 100 in a retracted position. In the retracted position, the tip 102 is within the vapor chamber 306 with the first end 302 forming a seal from ambient air, and the second end 304 substantially forms a seal around the elongated portion 318 so that the tip 102 extending from the opening 320 is within the vapor chamber 306 and substantially sealed from the ambient air. The back tip 322 makes contact with the feeder 316 so that the writing fluid stored in the feeder 316 conveys through the nib 308 and to the tip 102 . In the retracted position, as the writing fluid evaporates from the tip 102 , the vapor is substantially sealed within the vapor chamber 306 . The volume in the vapor chamber 306 may be minimized to limit the evaporation of the writing fluid. FIG. 5 illustrates the writing instrument 100 in a protracted position. To write, the plunger 112 is activated or pushed towards the second barrel 108 . This causes the first and second cartridges 312 and 314 , the nib 308 , and the tip 102 to move forward towards the first opening 106 . The resisting member 326 resists against the pushing force until the gear 328 engages to lock the plunger 112 in the protracted position. As the tip 102 pushes against the first end 302 , the first end 302 opens to allow the tip 102 to pass through and extend through the first opening 106 . Once the tip 102 is in a protracted position, it is ready for writing onto a writing surface. In the protracted position, the elongated portion 318 of the first cartridge 312 may extend from the first opening 106 along with the tip 102 . The elongated portion 318 may assist in guiding the tip through the first end 302 of the enclosure member 300 and the first opening 106 . The elongated portion 318 may have a vent 307 for allowing air into the feeder 316 when the writing instrument 100 is in use. The vent 307 may be a passage formed in the wall of the elongated portion 318 , or formed between the inner wall of the elongated portion 318 and the nib 308 . With the later formation of the vent 307 , the size and configuration of the vent 307 may be varied by altering the outer wall configuration of the nib 308 . The vent or passage may be also formed within the feeder with a certain pore size to allow air to pass to the feeder. The elongated portion 318 may be configured so that it resides within the resisting member 326 . As illustrated in FIG. 4 , in the retracted position, the resisting member 326 is in an uncompressed state. As illustrated in FIG. 5 , in the protracted position, the resisting member 326 is in a compression state. As the plunger 112 is activated between the retracted and protracted positions, the resisting member 326 exerts expansive force between the second end 304 of the enclosure member 300 and the edge 325 of the first cartridge 312 to cause the tip 102 to move in and out of the enclosure member 300 . The plunger 112 and resisting member 326 described above may be employed in a variety of ways. For example, twist cam mechanisms and latching push button mechanisms may be used, or any other return mechanisms known to one skilled in the art. FIGS. 6 and 7 illustrate perspective views of the first end 302 and the second end 304 of the enclosure member 300 . The first and second ends 302 and 304 may be integral or formed from separate pieces of elastomeric material. The first end 302 has a lip 600 with a slit 602 that opens and closes as the tip 102 moves in and out of the enclosure member 300 . The elongated portion 318 may guide the tip 102 through the lip 600 as it moves through the lip 600 . In the retracted position, the lip 600 substantially seals the ambient air from the vapor chamber 306 as shown in FIG. 7 . The second end 304 may have an outer configuration 700 in the form of a ring. The outer configuration may have an outer diameter sized to fit within the inner wall of the housing 101 , or in the first barrel portion 104 . The size of the diameter may vary so that the second end may seal around the inner wall of the housing 101 , or a gap may be formed between the second end and the housing. The second end 304 may have an inner configuration 702 sized to allow the elongated portion 318 to slide forward and backwards along the longitudinal direction. The inner configuration 702 may be also sized so that it forms a substantially airtight seal around the elongated portion 318 as it slides along the longitudinal direction. This allows the vapor chamber 306 to be formed within the enclosure member 300 that is substantially sealed from the ambient air when the lip 600 is closed. In addition, the vent 307 may be formed near the tip 102 so that the enclosure member 300 may substantially seal the vent and the tip when the writing instrument 110 is in a retracted position. The enclosure member 300 may be configured to minimize the size of the vapor chamber 306 . This may be accomplished by tapering the thickness of the second wall 704 from the outer configuration 700 towards the inner configuration 702 . The tapering second wall 704 may conform to provide the inner configuration that serves to guide and seal around the elongated portion 318 to minimize the space in the vapor chamber 306 . The inner configuration 702 may be configured to minimize the resistance on the elongated portion 318 as it slides back and forth. The inner configuration may have one or more edges 706 and 708 separated by a depression, reducing the thickness of the second wall 704 with every depression. Reducing the wall thickness with the edges 706 and 708 reduces the friction between the inner configuration 702 and the elongated portion 318 . FIG. 6 illustrates the front perspective view of the enclosure member 300 . From the second end 304 , the enclosure member 300 may be configured to taper down towards the lip 600 . This may be done to minimize the space within the vapor chamber 306 . The tapering may be done so that the inner wall of the enclosure member 300 substantially conforms to the shape of the tip 102 and the elongated portion 318 without touching when the writing instrument is in a retracted position. The enclosure member tapers to form the lip 600 having a slit like opening 602 that opens to allow the tip 102 to protrude out. FIG. 8 illustrates a cross-sectional view around the first barrel 104 along with its internal mechanisms including a clip 301 over the enclosure member 300 . As the elongated portion 318 moves towards the protruding position, the open end 800 of the elongated portion 318 may first engage with the inner wall 802 of the enclosure member 300 to open the lip 600 so that the tip 102 may freely extend through the lip 600 . This way, the integrity and shape of the tip 102 may be maintained. The open end 800 may have a bulging configuration to further assist .in pushing the lip 600 open as it engages with the inner wall 802 . The first barrel 104 may also have slots 804 formed along a portion around the first barrel 104 to allow the clip 301 to open without being restrained by the inner wall of the first barrel 104 . The slots 804 may be formed near the edge 806 of the clip 301 that extends out the most as the clip opens. This allows first barrel 104 to have a nominal outer configuration or minimize the diameter of the housing 101 . FIG. 9 is another cross-sectional view around the first barrel 104 where the writing instrument is in a retracted position. Here, the tip 102 extends further from the open end 900 of the elongated portion 318 so that the tip 102 may engage with the inner wall 802 of the enclosure member 300 first to open the lip 600 . As the tip 102 extends further towards the protracted position, the open end 900 of the elongated portion 318 engages with the lip 600 to keep the lip opened. Note that in the retracted position, the lip 600 and the inner configuration 702 of the second end 304 substantially seal the tip 102 from the ambient air in a small space to minimize evaporation of the ink. That is, the vapor chamber 306 may be configured to seal the tip 102 with minimal volume. This may be done by providing the second end 304 adjacent to the end of the tip 102 and providing the first end adjacent to the front end of the tip 102 . In addition, the second end 304 tapers towards the inner configuration 702 to provide as much distance as possible between the first end and the second end with minimal volume. The inner wall 802 may taper from the second end 304 to the first end 302 to form the lip 600 to minimize the volume of the vapor chamber 306 as well. FIG. 9 also illustrates divots 902 formed within the inner wall 904 of the first barrel 104 to allow the clip 301 to expand without being constrained by the inner wall of the first barrel 104 . The enclosure member 300 may be made of one piece as described above, or from a number of pieces. For example, the outer configuration 700 of the second end 304 may be coupled to the inner wall of the housing, and the first end 302 with the lip 600 may be coupled to the housing closer to the first opening 106 , where the space between the first and second ends form the vapor chamber. FIGS. 10 and 11 illustrate the front and rear perspective views of the clip 301 , respectively. The clip 301 may include a support rim 1000 , and two bias arms 1002 . The support rim 1000 is configured to receive the second end 304 of the enclosure member 300 . The bias arms 1002 are configured to taper towards the pinch end 1004 and house the enclosure member 300 as illustrated in FIGS. 8 and 9 . The pinch end 1004 is placed over the lip 600 of the enclosure member 300 to apply compression force over the lip 600 to assist in sealing the lip 600 . The bias arms 1002 may be formed from a material that is resistant to fatigue and the development of positional memory (e.g., spring steel.) The bias arms 1002 may be configured so that when it is compressing over the lip 600 in the retracted position, it may apply sufficient compression force to assist in substantially sealing the lip 600 . As the elongated portion 318 engages with the inner wall of the enclosure member 300 to open the lip 600 , the bias arms 1002 may release, at least, partially the compression force on the lip 600 to minimize the friction between the lip 600 and the elongated portion 318 as it moves towards the protracted position. FIG. 12 illustrates a perspective view of another enclosure member 1200 having a first end 1202 with a lip 1206 and a second end 1204 . The enclosure member 1200 may have cavities 1208 , one on each side of the enclosure member 1200 , adapted to receive a clip 1400 on each side as illustrated in FIG. 14 , as discussed in more detail below. FIG. 13 illustrates the perspective view of the second end 1204 of the enclosure member 1200 . The second end 1204 has an inner configuration 1300 adapted to receive the elongated portion 318 with the nib 308 inside. As the tip 102 moves between the retracted and protracted positions, the elongated portion 318 correspondingly moves axially relative to the inner configuration 1300 . The inner configuration 1300 substantially seals around the elongated portion 318 during this axial movement. The inner configuration 1300 may have an edge 1302 beveled to minimize the friction between the second end 1204 and the elongated portion 318 . Alternatively, the inner configuration 1300 may have a rounded edge to minimize the friction with the elongated portion 318 . In addition, within the inner wall of the first barrel 104 there may be channels that are aligned to associate with the cavities 1208 so that the enclosure member is properly aligned in relation to the first barrel during the assembly of the writing instrument. FIG. 14 illustrates the clip 1400 for the enclosure member 1200 . The clip 1400 may be placed over the enclosure member 1200 so that the bias arms 1406 fit into the cavities 1208 formed in the enclosure member 1200 . The clip 1400 has a pinch end 1402 adapted to compress the lip 1202 and the back support end 1404 on the opposite side to support the second end 1204 so that the enclosure member substantially maintains its shape as the tip moves between the retracted and protracted positions. That is, the clip 1400 may act as a back bone so that the enclosure member 1200 substantially maintains its shape as the elongated portion 318 moves back and forth along the inner configuration 1300 and the lip 1206 . The width of the pinch end 1402 may cover at least the width of the slit 1206 in FIG. 12 to substantially seal the vapor formed in the vapor chamber of the enclosure member 1200 from escaping through the slit. The clip 1400 may have bias arms 1406 that are configured to provide sufficient compression force to the lip 1206 in the retracted position, but relieve at least a portion of its compression force when the tip 102 or the open end of the elongated portion 318 engages with the inner wall 802 of the enclosure member 1200 . This way, the friction between the elongated portion 318 and the inner configuration 702 may be minimized so that less force is required to activate the plunger 112 . FIG. 15 illustrates an enclosure member 1500 having a clip member 1502 that is integrated into the enclosure member 1500 . The clip 1502 may be formed from two separate pieces integrated into the second end 1504 of the enclosing member 1500 . Each piece may have a “U” shape configuration. The clip 1502 may have a pinch end 1506 that substantially seals the lip 1508 of the enclosure member 1500 in the retracted position. FIG. 16 illustrates the tip 102 engaging with the lip 1508 to open the lip 1508 . As the tip 102 further extends towards the protracted position as illustrated in FIG. 17 , the elongated portion 318 engages with the lip 1508 and keeps the lip 1508 open. FIG. 18 illustrates a disassembled perspective view of an alternative writing instrument 1800 . In this example, the writing instrument 1800 includes a plunger 1802 , feeder 1804 , the writing tip 1806 , the cartridge 1808 with an elongated portion 1809 , resisting member 1810 , the enclosure member 1812 , the clip 1814 , and the housing 1816 . For assembly, the writing tip 1806 may be inserted into the cartridge 1808 followed by the feeder 1804 and the plunger 1802 , which seals the back end of the cartridge 1808 . The enclosure member 1812 and the clip 1814 may be assembled as discussed above, and may be disposed into the housing 1816 . The resisting member 1810 may be then inserted into the housing 1816 followed by the cartridge 1808 . Alternatively, bias arms 1002 may be coupled to the first barrel portion of the housing to engage with the lip of the enclosure member to assist in sealing the lip. In addition, the internal mechanism described above may be manufactured in various sizes appropriate for different diameters of the writing instrument or other non-writing devices for applying volatile liquids such as cosmetics, paint, and the like. FIG. 19 illustrates an enlarged cross-sectional view of the first cartridge 312 . The leading section 1900 of the elongated portion 318 may have three sections, a first leading section 1902 , a second leading section 1904 , and a third leading section 1906 , where the second leading section 1904 is between the first and third leading sections 1902 and 1906 . In the retracted position, the first leading section 1902 is within the vapor chamber 306 , the second leading section 1904 substantially forms a seal with the second end 304 , and the third leading section 1906 is on the rear side of the second end 304 . The first leading section 1902 tapers downward towards the opening 320 along the longitudinal axis to make it easier for the first leading section 1902 to pass through the slit like opening in the lip of the enclosure member. The second leading section 1904 is substantially flat along the longitudinal axis to form a seal with the inner configuration of the second end 304 in the retracted position. The circumference around the second leading section 1904 may be about the same or slightly greater than the size of the inner configuration 702 and 1300 in the second end 304 to form a seal. The third leading section 1906 tapers upward towards the opening 320 along the longitudinal axis so that as the third leading section 1906 is pushed into the second end 304 , the circumference around the third leading section 1906 is reduced to minimize the friction between the third leading section 1906 and the second end 304 . This in turn minimizes the wear along the inner configuration of the second end 304 . FIG. 19 also illustrates that the third leading section 1906 may have a recess area 1908 formed behind the second end 302 of the enclosure member 300 in the retracted position to control the release of vapor formed within the vapor chamber 306 . In the retracted position, vapor may form within the vapor chamber 306 as writing fluid evaporates through the tip 102 . As the tip 102 moves from the retracted position to the protracted position, the recess area 1908 formed in the elongated portion 318 slides into the second end 304 forming a gap between the third leading section 1906 and the inner configuration. The gap may be formed on the second end 304 before the tip 102 passes through the first end 302 . As such, any vapor inside the vapor chamber 306 is released through the gap on the back side or second end 304 rather than through the slit in the lip on the front end or first end 302 of the enclosure member 300 . This eliminates the potential problem of releasing vapor through the first opening 106 of the writing instrument 100 , which can spray ink spots onto the writing surface. FIG. 20 illustrates a front view of the opening 320 formed along the first leading section 1902 . Within the opening 320 there may be at least one tooth 2000 adapted to engage with the nib 308 to hold the tip 102 in a predetermined position. FIG. 21 shows an enlarged view of the tip 102 and the nib 308 . The tip 102 may have an edge 2100 with a pitch angle to allow the tip 102 to penetrate through the slit 602 in the lip 600 more easily. The tooth 2000 inside the opening 320 may hold the tip 102 so that the edge 2100 of the tip 102 may be aligned relative to the orientation of the slit 602 on the lip 600 . With the enclosure member 300 and the edge 2100 aligned and held in a predetermined position, the tip 102 may cycle in and out of the slit 602 without damaging the slit 602 . This also ensures that the edge 2100 of the tip 102 protracts consistently in relation to the first and second barrels. That is, the edge of the tip 102 is substantially prevented from rotating in relation to the first and second barrels. In embodiments where the writing instrument 100 has a side clip on the second barrel or an asymmetrically shaped outer configuration, having the tip 102 protract consistently allows a user to hold the writing instrument as intended as well. The enclosure member 300 may be made of a material that is durable and flexible so that the slit 602 does not wear out after many cycles of the tip 102 moving in and out of the slit 602 . The material may have low permeability to vapor and air to seal the tip 102 from the outside air. The material may be also soft enough to provide a better seal around the imperfections in the slit and the inner configuration. In this regard, the material may have a shore hardness of about 30 to about 80, and in particular in the range of about 50 to 65. The enclosure member may be formed from a variety of materials such as silicon, butyl-rubber, and thermoplastic elastomer with thermoplastic rubber that has low-permeability to vapor. A variety of methods may be used to form the enclosure member using silicone such as injection molding, blow molding, extrusion molding, and other methods known to one skilled in the art. For alcohol-based writing fluid with higher evaporation rate, butyl rubber may be compression molded or other methods known to one skilled in the art may be used to form the enclosure member. Alternatively, the enclosure member may be formed from thermoplastic elastomer with thermoplastic rubber that has low-permeability to vapor. Such a material is manufactured by Advance Elastomer Systems, L. P. 388 South Main Street, Akron, Ohio 44311, under the name of Trefsin® that can be formed into the enclosure member 300 using a variety of methods, such as injection molding, blow molding, and extrusion molding. Although the invention has been described with specific reference to certain exemplary embodiments, other advantages, and modifications and variations of the invention, including adaptation or incorporation of the inventive seal into writing instruments of different sizes and configurations, are all within the scope of the invention as defined by the claims and equivalents thereof.
A retractable writing instrument that substantially prevents writing fluid from evaporating through the tip when the tip is in a retracted position to eliminate the need for a cap. Within the writing instrument is an enclosure member that has a vapor chamber. In the retracted position, the tip of the writing instrument is within the vapor chamber to substantially seal the tip from ambient air so that writing fluid does not evaporate through the tip. The enclosure member has a lip that opens to allow the tip to move forward and extend from the writing instrument so that writing fluid can be delivered to the writing surface for writing. When the tip is moved back into the retracted position the lip closes to substantially seal the tip from the ambient air. An external compression force may be applied to the lip to assist in sealing the lip. The enclosure member may be made of a material that is durable so that the lip does not wear out after many cycles of moving the tip between the retracted and protracted positions, such as silicone, butyl rubber, and thermoplastic vulcanizate (TPV) material including butyl rubber cross-linked with polypropylene.
1
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is a continuation application of U.S. patent application Ser. No. 11/096,917, filed Apr. 1, 2005, which claims the priority of U.S. Provisional Application Ser. No. 60/560,199, filed Apr. 7, 2004 and entitled “Processor Pipeline With Multithreaded Support,” which is incorporated by reference herein. [0002] The present application is also related to U.S. patent application Ser. No. 10/841,261, filed May 7, 2004 and entitled “Processor Reduction Unit for Accumulation of Multiple Operands With or Without Saturation,” which is incorporated by reference herein. FIELD OF THE INVENTION [0003] The present invention relates generally to the field of digital data processors, and more particularly to multithreading and pipelining techniques for use in a digital signal processor (DSP) or other type of digital data processor. BACKGROUND OF THE INVENTION [0004] Pipelining is a well-known processor implementation technique whereby multiple instructions are overlapped in execution. Conventional pipelining techniques are described in, for example, John L. Hennessy and David A. Patterson, “Computer Architecture: A Quantitative Approach,” Third Edition, Morgan Kaufmann Publishers, Inc., San Francisco, Calif., 2003. [0005] FIG. 1A shows an example involving the execution of two instructions without any overlap. In this example, the two instructions are an integer add instruction addi r 0 , r 2 , 8 , and an integer multiplication instruction muli r 8 , r 3 , 4 . The first instruction, addi, performs an addition of the contents of register r 2 and an immediate value 8 , and stores the result in register r 0 . It is assumed for simplicity and clarity of illustration that each of the instructions includes the same four pipeline stages, denoted instruction fetch (IF), read (RD), execute (EX) and writeback (WB). [0006] In the first stage (IF) instructions are fetched from memory and decoded. In the second stage (RD) the operands are read from the register file. In the third stage (EX) the addition is performed. Finally, in the fourth stage (WB) the results are written back into the register file at location r 0 . When the addi instruction has completed, the next instruction muli is started. The muli instruction performs an addition of the contents of register r 3 and an immediate value 4 , and stores the result in register r 8 . [0007] FIG. 1B shows the same two instructions but depicts how they may be overlapped using a conventional pipelining technique. Each of the pipeline stages (IF, RD, EX and WB) is generally executed on a clock boundary. The second instruction, muli, may be started on the second clock cycle without requiring additional hardware. The hardware associated with the IF, RD, EX and WB stages are shared between the two instructions, but the stages of one instruction are shifted in time relative to those of the other. [0008] FIG. 2 illustrates a complication that may arise in a pipeline implementation. In this example, the muli instruction requires as an operand the contents of register r 0 , and thus cannot read r 0 until the addi instruction has computed and written back the result of the addition operation to r 0 . Processing of the muli instruction begins on the next clock cycle following the start of the addi instruction, but this process must stall and wait for the execution and writeback stages of the addi instruction to complete. The empty cycles the muli instruction must wait for its operands to become available are typically called “bubbles” in the pipeline. [0009] In single-threaded processors, a common method for reducing pipeline bubbles is known as bypassing, whereby instead of writing the computed value back to the register file in the WB stage, the result is forwarded directly to the processor execution unit that requires it. This reduces but does not eliminate bubbles in deeply pipelined machines. Also, it generally requires dependency checking and bypassing hardware, which unduly increases processor cost and complexity. [0010] It is also possible to reduce pipeline stalls through the use of multithreading. Multithreaded processors are processors that support simultaneous execution of multiple distinct instruction sequences or “threads.” Conventional threading techniques are described in, for example, M. J. Flynn, “Computer Architecture: Pipelined and Parallel Processor Design,” Jones and Bartlett Publishers, Boston, Mass., 1995, and G. A. Blaauw and Frederick P. Brooks, “Computer Architecture: Concepts and Evolution,” Addison-Wesley, Reading, Mass., 1997, both of which are incorporated by reference herein. [0011] However, these and other conventional approaches generally do not allow multiple concurrent pipelines per thread, nor do they support pipeline shifting. [0012] Accordingly, techniques are needed which can provide improved pipelining in a multithreaded digital data processor. SUMMARY OF THE INVENTION [0013] The present invention in an illustrative embodiment provides a multithreaded processor which advantageously allows multiple concurrent pipelines per thread, and also supports pipeline shilling. [0014] In accordance with one aspect of the invention, a multithreaded processor comprises a plurality of hardware thread units, an instruction decoder coupled to the thread units for decoding instructions received therefrom, and a plurality of execution units for executing the decoded instructions. The multithreaded processor is configured for controlling an instruction issuance sequence for threads associated with respective ones of the hardware thread units. On a given processor clock cycle, only a designated one of the threads is permitted to issue one or more instructions, but the designated thread that is permitted to issue instructions varies over a plurality of clock cycles in accordance with the instruction issuance sequence. The instructions are pipelined in a manner which permits at least a given one of the threads to support multiple concurrent instruction pipelines. [0015] In the illustrative embodiment, the instruction issuance sequence is determined using a token triggered threading approach. More specifically, in an arrangement in which the processor supports N threads, over a sequence of N consecutive processor clock cycles each of the N threads is permitted to issue instructions on only a corresponding one of the N consecutive processor clock cycles. [0016] The illustrative embodiment allows each of the threads to issue up to three instructions on its corresponding one of the processor clock cycles. The instructions are pipelined such that at least five separate instruction pipelines can be concurrently executing for different ones of the threads. [0017] The pipelined instructions in the illustrative embodiment include a load/store instruction, an arithmetic logic unit instruction, an integer multiplication instruction, a vector multiplication instruction, and a vector multiplication and reduction instruction. [0018] In accordance with another aspect of the invention, the vector multiplication and reduction instruction is pipelined using a number of stages which is greater than a total number of threads of the processor. For example, the vector multiplication and reduction instruction may comprise a pipeline with at least eleven stages, including an instruction decode stage, a vector register file read stage, at least two multiply stages, at least two add stages, an accumulator read stage, a plurality of reduction stages, and an accumulator writeback stage. The accumulator read stage may be combined with another of the stages, such as an add stage. Pipelines for respective vector multiplication and reduction instructions may be shifted relative to one another by a plurality of pipeline stages. [0019] The present invention in the illustrative embodiment provides a number of significant advantages over conventional techniques. For example, a higher degree of concurrency is provided than that achievable using conventional approaches. Also, the need for dependency checking and bypassing hardware is eliminated, since computation results are guaranteed to be written back to the appropriate register file before they are needed by the next instruction from the same thread. Furthermore, the techniques help to limit processor power consumption. BRIEF DESCRIPTION OF THE DRAWINGS [0020] The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which: [0021] FIGS. 1A and 1B show examples of instruction execution using conventional approaches; [0022] FIG. 2 illustrates the manner in which stalls can occur in a conventional processor pipeline; [0023] FIG. 3 shows an example of a pipeline of a multithreaded pipelined processor in an embodiment of the invention; [0024] FIG. 4 shows an example of a multithreaded processor in which the present invention may be implemented; [0025] FIG. 5 is a diagram illustrating an example token triggered multithreading approach that may be utilized in an embodiment of the invention; [0026] FIG. 6 shows a number of example pipelines in an embodiment of the invention; and [0027] FIG. 7 illustrates the manner in which pipelines can be shifted to permit computation cycles which are longer than issue cycles, in accordance with one embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION [0028] The present invention will be described in the context of an exemplary multithreaded processor. It should be understood, however, that the invention does not require the particular arrangements shown, and can be implemented using other types of digital data processors and associated processing circuitry. [0029] A given processor as described herein may be implemented in the form of one or more integrated circuits. [0030] The present invention in an illustrative embodiment provides a pipelining technique suitable for use in a multithreaded processor. With this technique, multiple instructions from multiple threads can be concurrently executed in an efficient manner. As will be described in greater detail below, the illustrative embodiment uses variable length execution pipelines, staggered execution, and rotated start execution, to provide concurrent execution while maintaining low power operation. The illustrative embodiment provides a higher degree of concurrency than that are achievable using conventional approaches. [0031] FIG. 3 shows an example of a multithreaded pipeline that removes the “bubbles” that are introduced through pipelined execution. As in the previous examples herein, it is assumed for simplicity and clarity of illustration in this example that the issued instructions each include the same four pipeline stages, namely, IF, RD, EX and WB. It is further assumed that there are three threads, and thus three hardware thread units or “contexts” issuing instructions in a sequential manner. In a typical implementation of a multithreaded processor, a given thread can generally be viewed in terms of hardware as well as software. The particular processor hardware associated with a given thread is therefore more particularly referred to herein as a hardware thread unit or simply a “context.” [0032] In this example, an integer add instruction addi r 0 , r 2 , 8 is initially issued by a first one of the contexts on a first clock cycle. The other two contexts issue instructions on respective subsequent clock cycles. It takes a total of three clock cycles for each of the contexts to issue an instruction. On a fourth clock cycle, the first context issues another instruction, namely an integer multiplication instruction muli r 8 , r 0 , 4 . [0033] More specifically, in cycle 1 , the IF stage of thread 1 is executed for the addi instruction. In cycle 2 , the IF stage of thread 2 executes while at the same time the RD stage of thread 1 executes. In cycle 3 , the IF stage of thread 3 executes, the RD stage of thread 2 executes, and the EX stage of thread 1 executes. In cycle 4 , the IF stage of thread 1 of the muli instruction executes concurrently with the WB stage of the addi instruction. Simultaneously, the EX stage of thread 2 executes and the RD stage of thread 3 executes. [0034] It can be seen from this example that multiple instructions from the same and different threads are overlapped and concurrently executing. It can also be seen that there are no bubbles in the pipeline even though the results of the addi instruction are required by the muli instruction. The FIG. 3 example therefore serves to illustrate that with an appropriately-configured pipeline and a sufficient number of threads, all hardware contexts may be executing concurrently even though there is only a single instruction issued per context per cycle. The particular number of threads and pipeline stages are purposes of illustration only, and not intended to reflect a preferred implementation. Those skilled in the art will be readily able to determine an appropriate number of threads and pipeline stages for a particular application given the teachings provided herein. [0035] As indicated previously, the present invention can be advantageously implemented in a multithreaded processor. A more particular example of a multithreaded processor in which the invention may be implemented is described in U.S. patent application Ser. No. 10/269,372, filed Oct. 11, 2002 and entitled “Multithreaded Processor With Efficient Processing For Convergence Device Applications,” which is commonly assigned herewith and incorporated by reference herein. This multithreaded processor may be configured to execute RISC-based control code, DSP code, Java code and network processing code. It includes a single instruction multiple data (SIMD) vector processing unit, a reduction unit, and long instruction word (LIW) compounded instruction execution. Examples of threading and pipelining techniques suitable for use with this exemplary multithreaded processor are described in U.S. patent application Ser. No. 10/269,245, filed Oct. 11, 2002 and entitled “Method and Apparatus for Token Triggered Multithreading,” now issued as U.S. Pat. No. 6,842,848, which is commonly assigned herewith and incorporated by reference herein. [0036] The invention can be implemented in other multithreaded processors, or more generally other types of digital data processors. Another such processor will now be described with reference to FIG. 4 . [0037] FIG. 4 shows an example of a multithreaded processor 400 incorporating a reduction unit 402 and an accumulator register file 406 . The processor 400 is generally similar to that described in U.S. patent application Ser. No. 10/269,372, but incorporates reduction unit 402 and accumulator register file 406 configured as described in the above-cited U.S. patent application Ser. No. 10/841,261. [0038] The multithreaded processor 400 includes, among other elements, a multithreaded cache memory 410 , a multithreaded data memory 412 , an instruction buffer 414 , an instruction decoder 416 , a register file 418 , and a memory management unit (MMU) 420 . The multithreaded cache 410 includes a plurality of thread caches 410 - 1 , 410 - 2 , . . . 410 -N, where N generally denotes the number of threads supported by the multithreaded processor 400 , and in this particular example is given by N=4. Of course, other values of N may be used, as will be readily apparent to those skilled in the art. [0039] Each thread thus has a corresponding thread cache associated therewith in the multithreaded cache 410 . Similarly, the data memory 412 includes N distinct data memory instances, denoted data memories 412 - 1 , 412 - 2 , . . . 412 -N as shown. [0040] The multithreaded cache 410 interfaces with a main memory (not shown) external to the processor 400 via the MMU 420 . The MMU 420 , like the cache 410 , includes a separate instance for the each of the N threads supported by the processor. The MMU 420 ensures that the appropriate instructions from main memory are loaded into the multithreaded cache 410 . [0041] The data memory 412 is also typically directly connected to the above-noted external main memory, although this connection is also not explicitly shown in the figure. Also associated with the data memory 412 is a data buffer 430 . [0042] In general, the multithreaded cache 410 is used to store instructions to be executed by the multithreaded processor 400 , while the data memory 412 stores data that is operated on by the instructions. Instructions are fetched from the multithreaded cache 410 by the instruction decoder 416 and decoded. Depending upon the instruction type, the instruction decoder 416 may forward a given instruction or associated information to various other units within the processor, as will be described below. [0043] The processor 400 includes a branch instruction queue (IQ) 440 and program counter (PC) registers 442 . The program counter registers 442 include one instance for each of the threads. The branch instruction queue 440 receives instructions from the instruction decoder 416 , and in conjunction with the program counter registers 442 provides input to an adder block 444 , which illustratively comprises a carry-propagate adder (CPA). Elements 440 , 442 and 444 collectively comprise a branch unit of the processor 400 . Although not shown in the figure, auxiliary registers may also be included in the processor 400 . [0044] The register file 418 provides temporary storage of integer results. Instructions forwarded from the instruction decoder 416 to an integer instruction queue (IQ) 450 are decoded and the proper hardware thread unit is selected through the use of an offset unit 452 which is shown as including a separate instance for each of the threads. The offset unit 452 inserts explicit bits into register file addresses so that independent thread data is not corrupted. For a given thread, these explicit bits may comprise, e.g., a corresponding thread identifier. [0045] As shown in the figure, the register file 418 is coupled to input registers RA and RB, the outputs of which are coupled to an arithmetic logic unit (ALU) block 454 , which may comprise an adder. The input registers RA and RB are used in implementing instruction pipelining. The output of the ALU block 454 is coupled to the data memory 412 . [0046] The register file 418 , integer instruction queue 450 , offset unit 452 , elements RA and RB, and ALU block 454 collectively comprise an exemplary integer unit. [0047] Instruction types executable in the processor 400 include Branch, Load, Store, Integer and Vector/SIMD instruction types. If a given instruction does not specify a Branch, Load, Store or Integer operation, it is a Vector/SIMD instruction. Other instruction types can also or alternatively be used. The Integer and Vector/SIMD instruction types are examples of what are more generally referred to herein as integer and vector instruction types, respectively. [0048] A vector IQ 456 receives Vector/SIMD instructions forwarded from the instruction decoder 416 . A corresponding offset unit 458 , shown as including a separate instance for each of the threads, serves to insert the appropriate bits to ensure that independent thread data is not corrupted. [0049] A vector unit 460 of the processor 400 is separated into N distinct parallel portions, and includes a vector file 462 which is similarly divided. The vector file 462 includes thirty-two registers, denoted VR 00 through VR 31 . The vector file 462 serves substantially the same purpose as the register file 418 except that the former operates on Vector/SIMD instruction types. [0050] The vector unit 460 illustratively comprises the vector instruction queue 456 , the offset unit 458 , the vector file 462 , and the arithmetic and storage elements associated therewith. [0051] The operation of the vector unit 460 is as follows. A Vector/SIMD block encoded either as a fractional or integer data type is read from the vector file 462 and is stored into architecturally visible registers VRA, VRB, VRC. From there, the flow proceeds through multipliers (MPY) that perform parallel concurrent multiplication of the Vector/SIMD data. Adder units comprising carry-skip adders (CSAs) and CPAs may perform additional arithmetic operations. For example, one or more of the CSAs may be used to add in an accumulator value from a vector register file, and one or more of the CPAs may be used to perform a final addition for completion of a multiplication operation, as will be appreciated by those skilled in the art. Computation results are stored in Result registers 464 , and are provided as input operands to the reduction unit 402 . The reduction unit 402 sums the input operands in such a way that the summation result produced is the same as that which would be obtained if each operation were executed in series. The reduced sum is stored in the accumulator register file 406 for further processing. [0052] When performing vector dot products, the MPY blocks perform four multiplies in parallel, the CSA and CPA units perform additional operations or simply pass along the multiplication results for storage in the Result registers 464 , and the reduction unit 402 sums the multiplication results, along with an accumulator value stored in the accumulator register file 406 . The result generated by the reduction unit is then stored in the accumulator register file for use in the next iteration, in the manner previously described. [0053] The accumulator register file 406 in this example includes a total of sixteen accumulator registers denoted ACC 00 through ACC 15 . [0054] The multithreaded processor 400 may make use of techniques for thread-based access to register files, as described in U.S. patent application Ser. No. 10/269,373, filed Oct. 11, 2002 and entitled “Method and Apparatus for Register File Port Reduction in a Multithreaded Processor,” which is commonly assigned herewith and incorporated by reference herein. [0055] The multithreaded processor 400 is well suited for use in performing vector dot products and other types of parallel vector multiply and reduce operations, as described in the above-cited U.S. patent application Ser. No. 10/841,261. [0056] The illustrative embodiment of the present invention utilizes an approach known as token triggered threading. Token triggered threading is described in the above-cited U.S. patent application Ser. No. 10/269,245, now issued as U.S. Pat. No. 6,842,848. The token triggered threading typically assigns different tokens to each of a plurality of threads of a multithreaded processor. For example, the token triggered threading may utilize a token to identify in association with a current processor clock cycle a particular one of the threads of the processor that will be permitted to issue an instruction for a subsequent clock cycle. [0057] FIG. 5 shows an example of token triggered threading for an implementation of a multithreaded processor in which the number of threads N is eight. In general, all of the threads operate simultaneously, and each accesses a corresponding instance of the thread cache 110 and data memory 112 . As shown in FIG. 5 , the eight threads are denoted Thread 0 , Thread 1 , Thread 2 , . . . Thread 7 , and are illustrated as being serially interconnected in the form of a ring. [0058] In accordance with the token triggered threading illustrated in FIG. 5 , all of the hardware thread units or contexts are permitted to simultaneously execute instructions, but only one context may issue an instruction in a particular clock cycle of the processor. In other words, all contexts execute simultaneously but only one context is active on a particular clock cycle. Therefore, if there are a total of C contexts it will require C clock cycles to issue an instruction from all contexts. Each clock cycle, one of the contexts issues an instruction, and the next thread to issue an instruction is indicated by a token. [0059] In the FIG. 5 example, the tokens are arranged in a sequential or round-robin manner, such that the contexts will issue instructions sequentially. However, tokens indicating the next context to issue an instruction may be arranged using other patterns, such as an alternating even-odd pattern. Also, as noted above, other types of threading may be used in conjunction with the present invention. [0060] Although token triggered threading is used in the illustrative embodiment, the invention does not require this particular type of multithreading, and other types of multithreading techniques can be used. [0061] FIG. 6 illustrates the manner in which example instruction functions may be pipelined in the multithreaded processor 400 in accordance with the present invention. In the illustrative embodiment of the invention, this type of pipelining is preferably utilized in conjunction with the token triggered threading described previously, but it is to be appreciated that numerous other combinations of pipelining and threading may be used in implementing the invention. [0062] The figure depicts example pipelines for Load/Store (Ld/St), Arithmetic Logic Unit (ALU), Integer Multiplication (I_Mul), Vector Multiplication (V_Mul), and Vector Multiplication and Reduction (V_Mul Reduce) instructions. In this implementation, up to three pipelines may be simultaneously started and all five may be in various phases of execution concurrently. [0063] The Ld/St pipeline has nine stages, denoted stage 0 through stage 8 . In the first stage, stage 0 (Inst Dec), an instruction is fetched and decoded. This stage is common to all five pipelines and determines which queue the instructions should be routed to. In stage 1 (RF Read), the register file operands are read. This will form the base address for the load or store operation. In the case of a store instruction, the data to be stored is also read. In stage 2 (Agen), any immediate values are added to the address and the full address is generated. In stage 3 (Xfer), the computed address is transferred to the memory subsystem. In stage 4 (Int/Ext), a determination is made as to whether the memory access is to internal or external memory. In stages 5 - 7 (Mem 0 , Mem 1 , Mem 2 ), the value is read from or written to memory. In stage 8 (WB), the value read from memory on a Load instruction is written into the register file. [0064] The ALU pipeline has seven stages, denoted stage 0 through stage 6 . As in the Ld/St pipeline, the first stage, stage 0 (Inst Dec), fetches and decodes all instructions. In stage 1 (Wait), a wait cycle is inserted. This allows the Ld/St and ALU hardware to share the same register file read ports. In the following stage, stage 2 (RF Read), the operands for the arithmetic function are read from the register file. Stages 3 and 4 (Exec 1 , Exec 2 ) then compute the arithmetic result (e.g., an add, compare, shift, etc.). In stage 5 (Xfer), the result is transferred to the register file. In stage 6 (WB), the result is written back into the register file. [0065] The I_Mul pipeline is similar to the ALU pipeline, as they share common architected resources. The figure indicates that the pipeline stages are identical except for an additional execution stage (Exec 3 ) in the I_Mul pipeline. Thus, an additional cycle is available for computing the result of a multiply. [0066] The V_Mul pipeline uses different architected resources than the previously-described ALU and I_Mul pipelines. It may therefore execute concurrently with those instructions without resource conflicts. Stage 0 (Inst Dec) is as in all instructions and allows for routing of the decoded instruction to the correct pipeline. In stage 1 (VRF Read) the vector register file operands are read. Stages 2 - 5 (MPY 1 , MPY 2 , Add 1 , Add 2 ) perform the multi-element vector arithmetic. The two add stages are present to convert the multiplication results from carry-save format back into two's complement format. Additionally, if the vectors only require simple arithmetic, this can be performed in the add stages. In stage 6 (Xfer), the results are transferred back to the vector register file, and in stage 7 (WB), the results are written back. [0067] The V_Mul Reduce pipeline is similar to the V_Mul pipeline except that an additional reduction operation is performed. The reduction takes the 4 vector element products, along with an accumulator operand, and reduces them to a single scalar element. Typically this involves adding all of the products to the accumulator or subtracting all of the products from the accumulator, although other combinations are possible. The V_Mul and V_Mul Reduce pipelines are the same until stage 5 . In stage 5 (Add 2 , ACC Read), an additional architected accumulator register file is read. This value is arithmetically combined with the vector elements and reduced to a single scalar. Four stages (Reduce 1 , Reduce 2 , Reduce 3 , Reduce 4 ) are devoted to this reduction and then the scalar value is written back to the accumulator register file (i.e., a different architected space from the vector register file) in stage 10 (ACC WB). [0068] If a single thread issued instructions each cycle as in FIG. 2 , bubbles would be induced in the pipeline. However, just as in the simplified case shown in FIG. 3 where there is only one type of pipeline, in the illustrative embodiment all five of the processor pipelines are interleaved and multithreaded to avoid bubbles. Each hardware thread unit issues up to three instructions in accordance with token triggered threading as shown in FIG. 5 . This ensures that no threads stall and all threads will complete without deadlock. [0069] As mentioned previously, in this implementation, all five processor pipelines may be simultaneously active with instructions from multiple hardware thread units. This fills potential bubbles in the pipeline with work from other thread units. [0070] It should be noted that a given V_Mul Reduce pipeline may be shifted in locality from a V_Mul pipeline in that the back-to-back reduction operations of the V_Mul Reduce pipeline do not cause bubbles. It appears that such a shift might lead to pipeline bubbles because the V_Mul Reduce pipeline is longer in duration than the number of hardware thread units (eight in this implementation). In other words, the computational cycle of the pipeline (eleven clock cycles for V_Mul Reduce) is longer than the issue cycle (each thread gets to issue once every eight clock cycles). In fact, this does not happen because the accumulator register file read phase is shifted from the V_Mul pipeline computations. [0071] FIG. 7 illustrates the manner in which multiple V_Mul Reduce pipelines can be shifted relative to one another so as to permit computation cycles which are longer than issue cycles. Note that the figure starts from cycle 5 of the first V_Mul Reduce instruction. Since there are eight thread units in this implementation, the next V_Mul Reduce instruction will issue on cycle 8 . As can be seen in the figure, the accumulator register file is written back in cycle 10 . The operands, however, are not read by the second instruction until cycle 13 . The second V_Mul Reduce pipeline can be thought of as being shifted in locality from the first V_Mul Reduce pipeline. This allows the lengthening of execution phases without causing bubbles in the pipeline. [0072] The illustrative embodiment described above advantageously allows multiple concurrent pipelines per thread and provides for pipeline shifting in deeply multithreaded pipelines. It also eliminates the need for dependency checking and bypassing hardware, since results are guaranteed to be written back to the register file before they are needed by the next instruction from the same thread. [0073] It should be noted that the particular processor, multithreading, pipelining and shifting arrangements shown in the figures are presented by way of illustrative example only, and additional or alternative elements not explicitly shown may be included, as will be apparent to those skilled in the art. [0074] It should also be emphasized that the present invention does not require the particular multithreaded processor configuration shown in FIG. 4 . The invention can be implemented in a wide variety of other multithreaded processor configurations. [0075] Thus, the above-described embodiments of the invention are intended to be illustrative only, and numerous alternative embodiments within the scope of the appended claims will be apparent to those skilled in the art. For example, the particular arrangement of hardware thread units, instruction decoder and execution units shown in FIG. 4 may be altered in other embodiments, and the invention should not be construed as requiring any particular type or arrangement of such elements. Also, as noted above, pipeline configurations, threading types and instruction formats may be varied to accommodate the particular needs of a given application.
A multithreaded processor comprises a plurality of hardware thread units, an instruction decoder coupled to the thread units for decoding instructions received therefrom, and a plurality of execution units for executing the decoded instructions. The multithreaded processor is configured for controlling an instruction issuance sequence for threads associated with respective ones of the hardware thread units. On a given processor clock cycle, only a designated one of the threads is permitted to issue one or more instructions, but the designated thread that is permitted to issue instructions varies over a plurality of clock cycles in accordance with the instruction issuance sequence. The instructions are pipelined in a manner which permits at least a given one of the threads to support multiple concurrent instruction pipelines.
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REFERENCE TO PENDING PRIOR PATENT APPLICATION [0001] This patent application claims benefit of pending prior U.S. Provisional Patent Application Ser. No. 60/629,055, filed Nov. 18, 2004 by Christian S. Hosford et al. for LANDFILL GAS PURIFICATION AND LIQUEFACTION PROCESS (Attorney Docket No. CRYO-1A PROV), which patent application is hereby incorporated herein by reference. SUMMARY OF THE INVENTION [0002] In one form of the invention there is provided a process for manufacturing liquid methane from a feedstock gas, wherein the feedstock gas is obtained from an alternative gas source generated by anaerobic digestion and comprising methane, carbon dioxide, nitrogen, oxygen, water vapor and hydrogen sulfide, the process comprising the steps of: (i) removing from the feedstock gas constituents which are incompatible with liquefaction, wherein removal is effected by pressure swing absorption, whereby to yield a mixture comprising methane, nitrogen and oxygen; and (ii) liquefying the mixture by cooling, and adjusting the temperature during cooling so as to remove nitrogen and oxygen, whereby to yield an output consisting primarily of liquid methane. BRIEF DESCRIPTION OF THE DRAWINGS [0005] This and other objects and features of the present invention will be more fully disclosed or rendered obvious by the following detailed description of the preferred embodiments of the invention, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein: [0006] FIG. 1 is a schematic view of a system and method of the present invention; [0007] FIG. 2 is a is a schematic view of a system and method of the present invention; and [0008] FIGS. 3-6 are a flowchart representing a method of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0009] This invention comprises a system and method for recovering methane gas from landfills (LFG) and producing liquefied methane, commonly referred to as LNG (a quality motor fuel). This invention comprises a system for collecting the landfill gas, a system for purifying and liquefying the landfill gas and a system for storing and dispensing liquefied methane (and other byproducts). [0010] See FIG. 1 . [0011] Gas is produced in a landfill by anaerobic digestion of some of the deposited waste. Landfill gas generally consists of methane and carbon dioxide from the anaerobic digestion, nitrogen and oxygen from air that is drawn into the collection system, and a variety of sulfur and non-methane organic compounds from the waste itself. The tops of landfills are sealed so that the LFG cannot escape into the atmosphere because there may be deleterious components in the gas that are considered to be air pollutants. [0012] The LFG collection system consists of a series of vertical or horizontal wells that convey the gas produced by anaerobic digestion to the inlet of a separator vessel. The separator vessel removes free water from the gas before the gas enters the inlet of a compressor. The LFG compressor raises the pressure of the LFG so that it can be delivered by pipeline to a flare where the combustible gases are incinerated before the LFG is discharged to the atmosphere, or the LFG gas is directed to the inlet of the LFG purification and liquefaction system, or to some other utilization method such as electrical power generation. The LFG collection system in itself is not unique to this invention. [0013] See FIG. 2 . [0014] The LFG liquefaction system consists of a series of processes that purify and liquefy the methane in the landfill gas and the system produces liquefied methane that is useful as a motor fuel or any other use that requires high purity methane, such as certain furnaces used in manufacturing processes. The LFG liquefaction plant consists of a purification process and a liquefaction process. The purification process removes the contaminants in the LFG, such as water and carbon dioxide, to a level that is compatible with the liquefaction process. This process operates in three modes: stand-by, production, and de-rime. The normal operating mode is the production mode. [0015] The production mode is the normal operating mode and specific provisions have been made to optimize the plant operations by recycling gas flows to conserve landfill gas and increase production. These provisions are noted in each process step where they are present. [0016] The stand-by mode is defined as the plant being ready to enter the production mode while maintaining safe pressures and temperatures in all parts of the plant. Specific provisions have been provided where required in the process. These provisions are noted in each process step where they are present. [0017] Regarding the de-rime mode, from time to time, the heat exchangers and other parts of the low temperature systems may become coated with frozen water or carbon dioxide and must be warmed to a temperature above the freezing temperature with circulating warm gas to remove them. [0018] Specific provisions are included in the production process system to accommodate all operating modes and to prevent the discharge of gas to the atmosphere, except via the landfill gas flare system, or in the event of a fire in the plant that might cause the pressure safety valves to open. These provisions are noted in each process step where they are present. [0019] The following description is intended to be read in conjunction with the four(4) sheets of block diagrams appended to the end of the description. [0020] See FIGS. 3-6 . [0021] The LFG enters the purification and liquefaction process at a positive gauge pressure, 15 to 17 psia, via a remotely controlled valve. The remotely controlled valve (RCV- 1 ) is used to isolate the liquefaction plant in the event of an emergency or when the liquefaction plant is shutdown. [0022] The 1 st step in the purification process is the removal of any free water in the gas with a cyclonic coalescing separator constructed of 300 series austenitic stainless steel, located downstream of RCV- 1 . The removed water is piped to the bottom of the vessel described in step 2 , via a pressure trap to prevent the flow of gas, where it is collected along with any water from steps 2 and 3 . [0023] The 2 nd step in the purification process employs a vessel filled with “iron sponge” adsorbent manufactured by various companies, such as “Sulfatreat”, specifically for the removal of hydrogen sulfide in gas streams, where the hydrogen sulfide reacts with the iron to form iron sulfate. Both the hydrogen sulfide absorbent and the spent adsorbent are non hazardous materials. The hydrogen sulfide absorber vessel is configured with a specially designed gas withdrawal device that ensures even flow distribution of the gas in the adsorbent thus improving the absorber efficiency. [0024] The 3 rd step in the purification process is the removal of any free water from the bottom of the of the absorber vessel that was formed by the reduction in gas pressure and/or temperature at the bottom of the absorber, or that has been piped from steps 1 and 6 . The water level in the bottom of the hydrogen sulfide removal vessel is monitored and the water is removed periodically to the leachate system of the landfill, or to an intermediate storage vessel where it is stored for removal by tanker truck, via a remotely controlled valve (RCV- 2 ) that is programmed to open for an adjustable period at programmed interval. [0025] The 4 th step in the purification process is the compression of the LFG to an elevated pressure of about 217 pound per square inch absolute (PSIA). The LFG compressor is configured with a pipe and control valve that allows the flow of cooled compressor discharge gas to the suction of the compressor when the compressor capacity control is set at minimum capacity, thus providing infinite control of the landfill gas into the downstream process. [0026] The 5 th step in the purification process is the cooling of the compressed landfill gas to a temperature that is about 15 degrees Fahrenheit above ambient air temperature, by ambient air in a heat exchanger that has electric motor driven fans that cause air to pass by extended surface tubes that have the process gas inside the tubes and, since the temperature of the gas inside the tubes is higher than the temperature of the air on the outside of the tubes, thus the gas is cooled. The cooling fans are controlled via a temperature control system to allow the discharge gas temperature to rise to 150 dF during the de-rime operating mode. [0027] The 6 th step in the purification process is the removal of any free water that has formed by the change in pressure and/or temperature using a coalescing cyclonic separator that is configured with a drainage vessel. The drainage vessel receives the water that has been separated, and discharges the water to the bottom of the vessel described in step 2 . The drainage vessel is configured with water level measurement instrumentation that controls the discharge of the water and provides an operator alarm if the level of the water rises to a level that adversely effects the operation of the coalescing cyclonic separator. [0028] The 7 th step in the purification process is the removal of any liquid or solid particles that may have passed the separator described in step 6 using a coalescing filter with a 10 micron filter element. This filter is configured with a drainage system that automatically drains any liquid from this filter to the condensate sump provided in Step 14 . The drain is configured with a flow control valve and a flow indicator to allow the operator to determine if there is condensate flowing and when the condensate stops flowing. [0029] The 8 th step in the purification process is drying the LFG in a pressure swing adsorber (PSA) that employs a molecular sieve as an adsorbent. The adsorbent in a pressure swing adsorber adsorbs water at high pressure and releases water at a low pressure with the assistance of a purge gas flow. The PSA employs two adsorber vessels in a parallel operation where one adsorber vessel is adsorbing water at high pressure and the other adsorber vessel is de-adsorbing water at low pressure and is purged with a flow of dry gas from steps 24 , 27 , and 29 of the liquefaction process. The PSA dryer reduces the water content of the LFG to a level of about 5 volumetric parts per million (5×10 −6 ). [0030] The 9 th step in the purification process is the removal of any particulate matter that may have been entrained in the drying process in step 8 filter with a twenty (20) micron filter element. [0031] The 10 th step in the purification process is the analysis of the LFG with a gas chromatograph and the measurement of the LFG with a meter that provides values for pressure, temperature and flow. [0032] The 11 th step in the purification process is the cooling of the LFG, to 12 dF, using a recuperative heat exchanger that recuperates the heat (refrigeration) from the gas exiting step 17 of the purification process in a counter flow process. The orientation/location of the heat exchanger is such that any organic condensate that might form from cooling the gas will flow by gravity to the next process step. [0033] The 12 th step in the purification process is the cooling of the LFG stream to a temperature of about −40 dF. that will cause heavy hydrocarbon compounds (C 6 +) to condense in a heat exchanger using a boiling refrigerant liquid such as ammonia, propane, or propylene. The temperature of the landfill gas is controlled by controlling the evaporating pressure of the refrigerant. The orientation/location/construction of this heat exchanger is such that any organic condensate that might form from cooling the gas will flow by gravity to the next process step. [0034] The 13 th step in the purification process is the removal of any organic compounds that may have condensed due to reduced pressure and/or change in temperature of the LFG by a coalescing cyclonic separator and a coalescing filter, the combination of which will remove more than 99% of any liquid particles equal or greater in diameter than 5 microns (meter×10 −6 ). The organic condensate removed from this separator is piped to a collection vessel that is shared by steps 7 & 14 , in a manner that allows condensate to drain by gravity and prevent the flow of gas to step 14 . [0035] The 14 th step in the purification process is the further removal of non-methane organic compounds (NMOC) in the LFG using a coalescing filter with a 99.97% removal efficiency of all liquid or solid particles equal or greater than 0.5 micron (meter×10 −6 ) in diameter. Condensate from this filter flows by gravity to the collection vessel described in step 13 . The condensate collection vessel is configured with instrumentation that monitors the liquid level in the vessel, controls the discharge of liquid in the vessel to maintain a level, and provides an operator alarm for high and low level. The discharge of condensate is piped to a collection vessel where it is stored for periodic removal by conventional mobile equipment in accordance with applicable local regulations as hazardous waste. [0036] The 15 th step in the purification process is the further removal of non-methane organic compounds (NMOC) in the LFG using activated carbon in a two vessel process configured with piping and valves such that the vessels may be configured to operate in series or parallel. The activated carbon (charcoal) absorbs non-methane organic compounds and metals, such as mercury, that could be detrimental to the materials of construction of the downstream process equipment. The LFG gas on inlet and outlet of the activated carbon is periodically sampled and analyzed in a gas chromatograph to determine the need for replacement of the carbon-absorbent. The piping is configured with block valves such that the carbon absorbent vessels may be isolated from the system when testing indicates levels of NMOC in excess of 1,000 volumetric parts per million. The spent carbon absorbent is mechanically removed from the absorption vessel and replaced with fresh absorbent. Spent carbon absorbent is recycled by the carbon supplier in a high temperature process. The carbon absorption system is configured with piping and a control valve to allow the process gas to bypass the absorption system during the de-rime operating mode. [0037] The 16 th step in the purification process is the removal of any particulate matter that may have been entrained into the LFG gas stream in the carbon absorption process by a purchased particulate filter with a 0.5 micron filter element. The particulate filter is configured with block and bypass valves so that the element can be changed without de-pressuring the entire plant. The filter inlet and outlet piping is configured with two block valves and a vent valve between the two block valves so that the filter can be isolated, de-pressured, and opened while maintaining the personal safety of the operator. [0038] The 17 th step in the purification process is the recovery of the refrigeration in the LFG in the recuperative heat exchanger in step 11 where the gas is heated to 60 dF. [0039] The 18 th step in the LFG purification process is the mixing of the LFG gas stream with the methane rich exhaust gas stream from the carbon dioxide liquefaction process step 41 , via step 39 . The flow of the exhaust gas stream is analyzed by a gas chromatograph and measured by a meter that provides values for pressure temperature and flow before it is mixed in a pipe with the LFG gas flow. [0040] The 19 th step in the purification process is the removal of carbon dioxide using a purchased rapid pressure swing adsorption (RPSA) system where the carbon dioxide is removed from the LFG stream in a process where CO2 is adsorbed by an adsorbent at high pressure, about 205 psia, and sent to the process gas outlet stream, and the CO2 is de-adsorbed by the adsorbent at low pressure of about 12 psia and sent to the vent stream. Thus the RPSA has one inlet stream, a process gas outlet stream and a vent gas outlet stream. The process gas outlet stream contains about 200 vppm of carbon dioxide and a percentage of the methane that was in the inlet gas stream. The vent, or exhaust, stream pressure is maintained by a compressor (blower) and the discharge of this compressor is piped to the carbon dioxide recovery system starting at step 34 . The RPSA is configured with a surge tank on each of the outlet streams. The surge tanks are designed to minimize the effects of flow/pressure oscillations in the stream in order to provide suction flow conditions that are consistent with the requirements of the downstream equipment. [0041] The 20 th step in the purification/liquefaction process is the compression of the process gas stream from the rapid pressure swing adsorption system to a pressure of about 250 psia. This pressure is consistent with the requirements of the downstream liquefaction processes. The process gas compressor is configured with an inlet surge vessel that is designed to attenuate the pressure swings from the RPSA to a level suitable for the reliable operation of the process gas compressor. The process gas compressor is configured with an outlet surge vessel that is designed to attenuate the pulsations from the reciprocating process gas compressor to levels that are consistent with the design of the downstream liquefaction plant process. The process gas compressor is configured with a water-glycol cooling system that cools the compressor heads and the compressor oil. The discharge of the compressor is also configured with an oil separator that removes oil from the process gas to a level of about 1 vppm, and a coalescing filter that reduces the oil level in the process gas. The process gas compressor is configured with piping and controls to allow flow from the compressor discharge to the compressor suction which allows the compressor operation to be controlled for all process flow conditions. [0042] The 21 st step in the purification/liquefaction process is the cooling of the process gas compressor discharge in a single pass counter flow heat exchanger with cold refrigerant gas on the cold side and warm process gas on the hot side. [0043] The 22 nd step in the purification/liquefaction process is the refrigeration of the process gas in a multi-pass plate heat exchanger where the process gas is first cooled by a recuperative heat exchange with process vent gas, and is then cooled to partial liquefaction temperature by cold nitrogen gas. The cold nitrogen gas is produced in a closed loop refrigeration system where a nitrogen storage tank maintains the suction pressure of a nitrogen compressor, the nitrogen compressor raises the nitrogen pressure, then an air cooled heat exchanger, where electric motor driven fans move air across extended surface tube that contain the hot nitrogen gas, thus cooling the nitrogen gas, then the nitrogen passes through a coalescing filter that removes any oil from the nitrogen, then the nitrogen flows to the suction of an expander driven compressor that further raises the nitrogen, then the compressor discharge is cooled in an air cooled heat exchanger, as described above, then the nitrogen gas is filtered to remove any solid or liquid particles greater than 0.5 micron in diameter, then the nitrogen enters a multi-pass heat exchanger where it is cooled by a combination of heat sinks, then the cooled nitrogen is expanded in the radial in-flow gas turbo-expander that powers the booster compressor, thus cooling the nitrogen gas to a temperature that is consistent with the liquefaction of methane at the discharge pressure of the booster compressor, then the cool nitrogen enters the multi-pass heat exchanger where it cools the process gas, then the nitrogen flows back to the suction of the nitrogen compressor via a heat recovery path in the multi-pass heat exchanger. A piping system with control valve is provided to allow process gas to by-pass the multi-pass heat exchanger in order to control the temperature of the gas/liquid flowing to step 23 . [0044] The 23 rd step in the purification/liquefaction process is the cooling of the process gas/liquid stream from −202 dF to −216 dF in a plate heat exchanger where the process gas/liquid flows through the warm pass of the heat exchanger and sub-cooled process gas from step 27 that flows in a counter current configuration in the cold pass of the heat exchanger. [0045] The 24 th step in the purification/liquefaction process is the separation of nitrogen and oxygen from the process gas in a residence time separator where the flow velocity of process gas/liquid mixture is reduced and a separation space and flow path is provided for gaseous constituents in the process gas/liquid. The gaseous portion of the flow stream exits the top of the separator via a de-mister device that is designed to coalesce liquid droplets from the gas flow and return the liquid to the separator. The pressure in this separator is maintained by a pressure control valve in the gaseous vent line from the separator. The gas flow from the separator is mixed with the gas flow from the separators in steps 27 and 29 and then flows to the multi-pass heat exchanger in step 22 where the refrigeration in the gas is recovered in a recuperative heat exchange process. This vent gas is employed to purge the adsorbent in the pressure swing dryer in step 8 of this process, and the wet gas is mixed with landfill gas upstream of the refrigerated dryers in the fuel gas processing for the engine generator set that powers this process, or is sent to flare. [0046] The 25 th step in the purification/liquefaction process is the refrigeration of the process gas stream by the Joules Thompson effect where the pressure is lowered by expansion of the high pressure liquid stream in a valve to a lower pressure. The outlet of the expansion valve is a mixture of gas and liquid at about 38 psia and −260 dF. [0047] The 26 th step in the purification/liquefaction process is the cooling of the liquid stream from step 29 by the cold liquid from step 25 in a counter flow heat exchanger. [0048] The 27 th step in the purification/liquefaction process is the separation of the gaseous fraction of the warm stream from step 26 in a residence time separator configured with a coalescing device that removes any liquid particles from the vent that exits the top of the separator where it mixes with the vent gas from step 24 . The liquid in the separator flows by gravity to the recuperative heat exchanger in step 23 . [0049] The 28 th step in the purification/liquefaction process is the heating of the liquid stream by electrical heaters to adjust the temperature of the liquid from about −246 dF to about −245 dF, to prepare for the final separation of inert gases. [0050] The 29 th step in the purification/liquefaction process is the separation of inert gases from the liquid methane in a residence time separator where the gaseous portion is vented from the top of the separator via a coalescing device that removes any liquid particles from the stream before it mixes with the vent gas from steps 27 and 24 . The liquid in the bottom of the separator flows to step 30 . [0051] The 30 th step in the purification/liquefaction process is the control of the level in the separator described in step 29 by a valve that is controlled by the liquid level in the separator and the discharge of the valve flows to the heat exchanger described in step 26 where it is sub-cools the liquid on the warm side of the exchanger. The system is configured with piping and a control valve so that the system flow may be directed to the suction of the landfill gas compressor described in step 4 during system start-up and during the de-rime operating mode. [0052] The 31 st step in the purification/liquefaction process is measurement of the flow from step 30 for temperature, pressure, and composition, and then the liquid flows in an insulated pipe to an insulated storage tank. [0053] The 32 nd step in the purification/liquefaction process is the final separation of liquid and gas in a storage tank that is configured with an inlet flow distribution device that distributes the inlet flow evenly with 20 flow outlets along the bottom of the horizontal storage vessel. The storage vessel is an insulated tank with a calculated heat flow from the surrounding atmosphere to the stored cryogenic liquid. This heat flow heats the stored liquid which causes a thermal separation of gas with a lower boiling point to evolve from the liquid as a gas. The evolved gases are collected in a constant velocity collection system that ensures that the flow of gases is evenly distributed above the gas/liquid surface of the stored liquid. The gaseous flow from the storage tank flows to the suction of the compressor described in step 3 via a pressure control valve. The control valve maintains a constant pressure in the storage tank. This pressure may be changed depending upon the composition of the LFG being processed to produce liquid methane gas that is consistent with the quality requirements of the consumer. [0054] The 33 rd step in the purification/liquefaction process is the removal of liquid from the storage tank on a periodic basis via a pump that is connected to the bottom of the storage tank at one end of the tank so that the withdrawal of liquid causes a minimum disturbance of the stored liquid. [0055] The 34th step in the purification/liquefaction process is the removal of the vent gas from the carbon dioxide removal system in step 19 where the vent gas flows to the suction of a positive displacement compressor via a surge tank. The surge tank is specifically configured to reduce the pressure fluctuations in the vent gas stream to minimize the transmission of pressure fluctuations to the discharge of the vent gas compressor. The vent gas compressor maintains a minimum suction pressure of about 12 psia on the vent of the carbon dioxide removal system to maximize the capacity of the adsorbent beds in the carbon dioxide removal system and discharges the vent gas at about 17 psia. The flow from the vent gas compressor is measured for flow, pressure, temperature, and composition. [0056] The 35 th step in the purification/liquefaction process is the compression of the discharge of the vent gas compressor from about 17 psia to about 320 psia, by the carbon dioxide compressor in a two stage gas compression process. Each compressor is configured with piping and controls to allow the discharge of the compressor to flow to the suction of the compressor in order to provide an infinite control of the compressor flows in combination with the compressor capacity controls. [0057] The 36 th step in the purification/liquefaction process is the cooling of the carbon dioxide compressor discharges from inter-stage and final discharge cooling with air cooled heat exchangers where electric motor driven fans move ambient temperature air across extended surface tubes that contain the compressed gas, thereby cooling the hot compressed gas to a temperature equal to that of the ambient air plus about 15 dF. The electric fans are controlled during the de-rime operating mode to provide warm gas for the de-rime of the carbon dioxide system components. [0058] The 37 th step in the purification/liquefaction process is the removal of trace amounts of oil in the compressed gas stream by a coalescing filter separator. [0059] The 38th step in the purification/liquefaction process is the cooling of the compressed gas to a temperature of about 70 dF in a heat exchanger by a controlled flow of liquid carbon dioxide from step 44 . The temperature of the liquid carbon dioxide is controlled by bypassing the heat exchanger to maintain a constant temperature that ensures the carbon dioxide does not become solid. [0060] The 39 th step in the purification/liquefaction process is the cooling of the compressed gas to a temperature of about 5 dF in a recuperative counter flow heat exchanger by the methane recycle gas flow from step 41 . The temperature of the compressed gas flow is controlled by bypassing compressed gas around the heat exchanger via a temperature control valve. [0061] The 40 th step in the purification/liquefaction process is the refrigeration of the compressed gas to a temperature of about −41 dF in a counterflow heat exchanger configured with boiling propylene on the cold pass and compressed gas on the hot pass. The compressed gas liquid mixture flow out of the heat exchanger by gravity to step 41 . [0062] The 41 st step in the purification/liquefaction process is the separation of methane from the liquid carbon dioxide in a high pressure residence time separator where the methane, and other gaseous components, flows out of the top of the separator to step 39 . The liquid flows out of the bottom of the separator to a Joules Thompson valve. [0063] The 42 nd step in the purification/liquefaction process is the cooling of the flow from step 41 from about −41 to −64 dF by the reduction in pressure in a Joules Thompson valve which results in a reduction of temperature and converts the liquid flow into a mixture of gas and liquid that flows to step 43 . [0064] The 43 rd step in the purification/liquefaction process is the separation of gas from liquid in a residence time separator where the gaseous portion of the stream exits the top of the separator via a coalescing filter and flows to the suction of the second stage CO2 compressor for recycling into the compressed gas stream. [0065] The 44th step in the purification/liquefaction process is the maintenance of the level in the separator described in step 41 where the liquid flows from the bottom of the separator to a pump in step 45 that is controlled by a liquid level controller on the separator. [0066] The 45th step in the purification/liquefaction process is the raising of the liquid CO2 to a pressure that is required for the storage of the liquid at a desired temperature and the liquid flows to the heat exchanger described in step 36 . [0067] The 46th step in the purification/liquefaction process is the heating of the CO2 liquid to a temperature of about −19 dF in the heat exchanger described in step 36 , then the liquid flow is measured for flow, temperature, pressure, and composition, and then flows to the CO2 storage tank via an insulated pipeline. [0068] The 47 th step in the purification/liquefaction process is the final separation of inert gasses from the liquid carbon dioxide in a pressurized storage tank that is configured with an inlet flow distribution device that distributes the flow evenly along the bottom of the horizontal storage tank. The CO2 storage tank is an insulated vessel where heat flows from the atmosphere through the insulation to the cold CO2 stored in the tank and causes the impurities in the CO2 to change from a liquid to a gas and rise to the surface of the liquid in the tank, where they are removed by a constant velocity vapor removal piping system that removes the gas from the tank. The evolved gases flow out of the storage tank and are returned to the inlet of the second stage CO2 compressor described in step 35 [0069] The 48 th step in the purification and liquefaction process is the loading of transport vehicles by a pump from the carbon dioxide storage tank.
A process for manufacturing liquid methane from a feedstock gas, wherein the feedstock gas is obtained from an alternative gas source generated by anaerobic digestion and comprising methane, carbon dioxide, nitrogen, oxygen, water vapor and hydrogen sulfide, the process comprising the steps of: (i) removing from the feedstock gas constituents which are incompatible with liquefaction, wherein removal is effected by pressure swing absorption, whereby to yield a mixture comprising methane, nitrogen and oxygen; and (ii) liquefying the mixture by cooling, and adjusting the temperature during cooling so-as to remove nitrogen and oxygen, whereby to yield an output consisting primarily of liquid methane.
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CROSS REFERENCE TO RELATED APPLICATIONS This application claims the benefit of a related U.S. Provisional Application Ser. No. 61/452,568, filed Mar. 14, 2011, the disclosure of which is incorporated by reference herein in its entirety. BACKGROUND Typically, in the drilling of a well, a borehole is drilled from the earth's surface to a selected depth and a string of casing is suspended and then cemented in place within the borehole. A drill bit is then passed through the initial cased borehole and is used to drill a smaller diameter borehole to an even greater depth. A smaller diameter casing is then suspended and cemented in place within the new borehole. Generally, this is repeated until a plurality of concentric casings are suspended and cemented within the well to a depth which causes the well to extend through one or more hydrocarbon producing formations. Oftentimes, rather than suspending a concentric casing from the bottom of the borehole to the surface, a liner may be hung either adjacent the lower end of a previously suspended and cemented casing, or from a previously suspended and cemented liner. A liner hanger is used to suspend the liner within the lower end of the previously set casing or liner. A setting tool disposed on the lower end of a work string is releasably connected to the liner hanger that is coupled with the top of the liner. The liner hanger, liner, setting tool, and other components are generally part of a liner hanger assembly. Another component, such as a liner top packer, may also be part of the liner hanger assembly, which may be used to seal the liner in the event of a poor cement job or to prevent gas flow while the cement sets. Typically, the liner top packer is set down on top of the liner hanger, and the liner top packer is set by the setting tool to seal the annulus between the liner and the previously set casing or liner. Liner top packers run with liner hangers typically include a tubular member with a bore in it that is coupled with the top end of the packer. This tubular member is commonly referred to as a polished bore receptacle (“PBR”) or a tieback receptacle (“TBR”). Because the liner does not run to the surface, the liner hanger has the ability to receive the PBR or TBR to connect the liner with a string of casing that extends from the liner hanger back to the surface. There is typically a seal or seal stack between the PBR and the body of the packer that allows axial motion of the PBR relative to the liner top packer body. A standard seal stack includes a plurality of annular spaced seals that fit within the interior of the PBR. Often, a PBR is coupled into an upper end of the packer, and production tubing is strung into the PBR with an appropriate seal to prevent leakage between the interior of the PBR and the production tubing. Various types of liner hangers have been proposed for hanging a liner from a casing string in a well. Most liner hangers are set with slips activated by the liner hanger running tool. Liner hangers with multiple parts pose a significant liability when one or more of the parts become loose in the well, thereby disrupting the setting operation and making retrieval difficult. In addition, wellbores often have tight spots and dog legs through which the liner hanger maneuvers, increasing the risk of the liner hanger becoming stuck or coming apart. Other liner hangers and running tools cannot perform conventional cementing operations through the running tool before setting the liner hanger in the well. Other liner hangers have problems supporting heavy liners with the weight of one million pounds or more. Some liner hangers successfully support the liner weight, but do no reliably seal with the casing string. After the liner hanger is set in the well, high fluid pressure in the annulus between the liner and the casing may blow by the liner hanger, thereby defeating its primary purpose. Another significant problem with some liner hangers is that the running tool cannot be reliably disengaged from the set liner hanger. This problem with liner hanger technology concerns the desirability to rotate the liner with the work string in the well, then disengage from the work string when the liner hanger has been set to retrieve the running tool from the well. Prior art tools have disengaged from the liner hanger by right-hand rotation of the work string, although some operators for certain applications prefer to avoid right-hand rotation of a work string to release the tool from the set liner. In addition, operators are presented with the problem of debris entering the running tool during disengagement of the liner. Accordingly, there exists a need for an improved downhole tool that has improved torque to wash and ream through tight spots and dog legs within the wellbore, that may avoid pre-setting while running, and that is able to more effectively maneuver through tight areas in the wellbore. SUMMARY In one aspect, the embodiments disclosed herein relate to a downhole tool that contains a body supported from a running string; and a releasing assembly for releasing from set liner hanger portions of the tool to be retrieved to the surface. The releasing assembly contains a connecting member for engaging the tool with a liner hanger, a piston hydraulically moveable in response to fluid pressure within the tool body from a lock position to a release position for releasing the connecting member, and a clutch for rotationally releasing the tool body from the liner hanger. The rotation of the running string moves a nut upward along the body so that the running string may then be picked up to disengage the tool from the liner hanger. In another aspect, embodiments disclosed herein relate to a method of releasing a running tool while supported on a running string from a liner hanger in a casing within a wellbore. The liner hanger is secured to a casing by a slip assembly to suspend the liner hanger from the casing. The method includes providing a releasing assembly about a tool body, wherein the releasing assembly includes a connecting member for engaging the running string with the liner hanger, a piston hydraulically moveable in response to fluid pressure within the tool body from a lock position to a release position for releasing the connecting member, a clutch for rotationally connecting the tool body with the liner hanger; and pressurizing the running string to move the piston to the release position for releasing the running string. In another aspect, embodiments disclosed herein relate to a method of setting a downhole tool. The method includes running the downhole to a desired depth in a wellbore; setting a liner hanger; activating hydraulically a setting tool; and compressing the setting tool. The compressing releases the setting tool from a liner. Other aspects and advantages of embodiments of the invention will be apparent from the following description and the appended claims. BRIEF DESCRIPTION OF DRAWINGS FIG. 1A shows a downhole tool in accordance with embodiments disclosed herein. FIG. 1B shows a cylinder assembly in accordance with embodiments disclosed herein. FIG. 1C shows a downhole tool in accordance with embodiments disclosed herein. FIG. 2A shows a downhole tool in a first position in accordance with embodiments disclosed herein. FIG. 2B shows a cross-sectional view of a downhole tool in a first, position in accordance with embodiments disclosed herein. FIG. 3A shows a downhole tool in a second position in accordance with embodiments disclosed herein. FIG. 3B shows a first cross-sectional view of a downhole tool in a second position in accordance with embodiments disclosed herein. FIG. 4A shows a downhole tool in a third position in accordance with embodiments disclosed herein. FIG. 4B shows a cross-sectional view of a downhole tool in a third position in accordance with embodiments disclosed herein. FIG. 5 shows a downhole tool in a fourth position in accordance with embodiments disclosed herein. FIG. 6 shows a downhole tool in a fifth position in accordance with embodiments disclosed herein. DETAILED DESCRIPTION In some aspects, embodiments disclosed herein relate to downhole tools. In some aspects, embodiments disclosed herein relate to downhole tools having a packer or a packer and liner hanger. In certain aspects, embodiments disclosed herein relate to downhole tools having a packer, liner hanger, and setting adaptor. In some aspects, embodiments disclosed herein relate to downhole tools having improved torque to run liner downhole. In certain aspects, embodiments disclosed herein relate to downhole tools having improved reliability for release of a setting adaptor. In some aspects, embodiments disclosed herein relate to hydro-mechanical downhole tools. In some aspects, embodiments disclosed herein relate to downhole tools having mechanical mechanisms to set a liner and a hydraulic lock to release a setting tool. In other aspects, embodiments disclosed herein relate to methods and apparatus for drilling and completing well bores. More specifically, embodiments disclosed herein relate to methods and apparatus for running liners downhole. In certain aspects, embodiments disclosed herein relate to methods and apparatus for hanging and/or setting liners in a wellbore. Embodiments disclosed herein are described below with terms designating orientation in reference to a vertical wellbore. These terms designating orientation should not be deemed to limit the scope of the disclosure. For example, embodiments of the disclosure may be with reference to a non-vertical wellbore, such as a horizontal or lateral wellbore. It is to be further understood that the various embodiments described herein may be used in various orientations, such as inclined, inverted, horizontal, vertical, etc., and in other environments, such as sub-sea wells, without departing from the scope of the present disclosure. The embodiments are described merely as examples of useful applications, which are not limited to any specific details of the embodiments herein. In addition, other directional terms, such as “above,” “below,” “upper,” “lower,” etc., are used for convenience in referring to the accompanying drawings. In general, “above,” “upper,” “upward,” and similar terms refer to a direction toward the earth's surface from below the surface along a wellbore, and “below,” “lower,” “downward,” and similar terms refer to a direction into the Earth from the surface (i.e., into the wellbore), but is meant for illustrative purposes only, and the terms are not meant to limit the disclosure. To hang a liner, a downhole tool may initially be attached to the lower end of a work string and releasably connected to the liner top packer/setting adapter, from which the liner is suspended for lowering into the wellbore beneath the previously set casing or liner. The liner top packer/setting adapter may include, but is not limited to, a packer, liner, or setting adapter. The assembly may be run downhole at a rate that does not adversely affect the well formations or the downhole tool. Referring to FIG. 1A , a downhole tool in accordance with embodiments described herein is shown. Embodiments of a downhole tool 60 disclosed herein may include a body 40 interfacing with hydraulic and mechanical components. In some embodiments, body 40 , which may include a mandrel or other tubular, is used to transmit torque to other components of tool 60 . In some embodiments, a downhole tool 60 may include a packer (not shown) as described in U.S. Pat. No. 4,757,860. Downhole tool 60 may include a shearing means having a gage ring 2 interfacing with a lock ring 3 , a set screw 4 , a shear screw 5 , and a key screw 6 . The gage ring 2 may provide a larger diameter surface than the body 1 to prevent snagging or catching of components of the downhole tool 60 on downhole surfaces as the downhole tool 60 is lowered into the wellbore. The gage ring 2 may be disposed above or below the lock ring 3 . Lock ring 3 may be used during compression to hold the gage ring 2 in place. In some embodiments, the downhole tool 60 may include a hydraulically actuated release mechanism, operable in conjunction with a right-hand rotation of body 40 , for releasing the downhole tool 60 from a liner top packer/setting adapter (not shown). In certain embodiments, the hydraulically actuated release mechanism may include a shear screw 5 , which may be configured to be sheared at a pre-determined amount of shearing force, as would be known by a person having ordinary skill in the art. For example, the shearing force may be in the range of 5 to 50 klbs (kilopounds). In some embodiments, the shear screw 5 may be configured to shear upon a shearing force in excess of 40 klbs. In other embodiments, the shear screw 5 may be configured to shear upon a shearing force in excess of 12 klbs. In some embodiments, the hydraulically actuated release mechanism may include a cylinder assembly 50 . FIG. 1B illustrates a cylinder assembly 50 in accordance with embodiments described herein. In some embodiments, cylinder assembly 50 may be disposed laterally through body 40 or concentrically disposed within body 40 . In certain embodiments, cylinder assembly 50 may include a hydraulic cylinder 7 interfacing with seal rings and o-rings, for example, seal split ring 8 , seal ring 9 , o-ring 11 , o-ring backup 10 , and o-ring 12 . In some embodiments, seal rings may be formed of a material having substantial elasticity to span certain portions of body 40 . In certain embodiments, the hydraulic cylinder 7 may include an actuator piston or ram (not shown) slidably engaged with body 40 . In some embodiments, the shear screw 5 may be disposed laterally through the body 40 , and engage the surface of body 40 . In other embodiments, hydraulic cylinder 7 may be pressurized using a ball drop method, explained in detail below. In certain embodiments, premature release of the liner top packer/setting adapter may be prevented because torsion is stored in cylinder assembly 50 and is not transmitted to the running nut 23 until the hydraulic mechanism is activated. In other words, cylinder assembly 50 may act to prevent premature release of liner top packer/setting adapter from downhole tool 60 . Returning to the exemplary downhole tool illustrated in FIG. 1A , in some embodiments, a top clutch 13 may interface with washer 29 , stop ring 30 , cover ring 31 , external ring 32 , key screw 15 , middle clutch 14 , and bottom clutch 16 , to lock one or more dogs. In some embodiments, the one or more dogs may include a torque dog spring 20 , a torque dog 17 , a torque dog clamp 18 , and a capscrew 19 , which may act in conjunction to engage torque dog 17 . In certain embodiments, the one or more dogs may be concentrically contained within an outer cylindrical housing. In some embodiments, top clutch 13 , middle clutch 14 , and bottom clutch 16 may each rotatably lock torque dog 17 such that rotation of body 40 results in the movement of one or more downhole components. Thus, the disposition of top clutch 13 , middle clutch 14 , and bottom clutch 16 convert the rotational movement of body 40 to a reciprocated motion and effectively function as a cam. In alternate embodiments, cover ring 31 and external ring 32 may not be required. For example, referring briefly to FIG. 1C , downhole tool 60 includes a key 55 disposed between top clutch 13 and middle clutch 14 . In certain embodiments, movement of body 40 may allow running nut 23 to move upward along right-hand threads due to right-hand rotation. In some embodiments, the internal flow path/bypass of running nut 23 may advantageously allow for debris to be removed from the interior space of a section 44 as the running nut 23 is threaded and/or unthreaded. Once the running nut 23 is unthreaded, the downhole tool 60 may be moved toward the wellbore surface to disengage the downhole tool 60 from the liner top packer/setting adapter. In some embodiments, downhole tool 60 may energize torque dog 17 using a spring assembly 21 in conjunction with key 22 , which interface with running nut 23 , set screw 24 , O-rings 25 and 26 , standing valve profile 27 , and bottom sub 28 . In some embodiments, the spring assembly 21 and key 22 may act to transfer torque to running nut 23 . In certain embodiments, exterior threads of running nut 23 may attach to a liner top packer/setting adapter (not shown) such that downhole tool 60 is attached to the liner top packer/setting adapter. In some embodiments, components of downhole tool 60 may permit the operator to achieve an improved torque while running downhole tool 60 down the wellbore and/or setting the liner top packer/setting adapter. The improved torque may allow for higher compression and improved mitigation of tight spots and dog legs within the wellbore. In certain embodiments, downhole tool 60 may achieve a torque in the range of 25,000 to 75,000 foot pounds (ft/lb) of force. In certain embodiments, downhole tool 60 may achieve a torque in excess of 25,000 ft/lb, or in excess of 40,000 ft/lb, or in excess of 50,000 ft/lb of force. Downhole tool 60 may also include other various design features such as various seals, washers, key screws and other various components to further facilitate the operation of the tool. In one embodiment, one or more pins 35 may be disposed on top clutch 13 . In certain embodiments guides may be of various geometries, such as round, rectangular, square, etc. In certain embodiments, substantially square pins 35 may be used to reduce point contact. FIG. 2A shows a downhole tool in a first position in accordance with embodiments disclosed herein. In FIG. 2A , downhole tool 260 is ready to attach to a liner top packer/setting adapter (not shown). In some embodiments, top clutch 213 engages to compresses torque dog 217 , which transmits a rotational force to portion 244 , and more specifically, running nut 223 . In exemplary embodiments, top clutch 213 may rotate to the left 30 degrees to disengage torque dog 217 and transmit the rotational force. In some exemplary embodiments, the rotational force causes running nut 223 to rotate four times to the left and connect the downhole tool 260 to the liner top packer/setting adapter. FIG. 2B shows a cross-sectional view of a downhole tool in a first position in accordance with embodiments disclosed herein. More specifically, FIG. 2B is a cross-sectional view taken through position B-B of downhole tool 260 prior to connection of the liner top packer/setting adapter. For example, FIG. 2B shows a view of the clutch assembly prior to the top clutch 213 being engaged to compress torque dog 217 and effectuate rotational movement of running nut 223 . As illustrated in FIG. 2A , torque dog 217 is disengaged and not viewable through window 218 . FIG. 3A shows a downhole tool in a second position in accordance with embodiments disclosed herein. In some embodiments, FIG. 3A shows downhole tool 360 after the liner top packer/setting adapter (not shown) is attached to downhole tool 360 such that downhole tool 360 is in a run in position. For example, top clutch 313 has been engaged and running nut 323 has rotated to attach the liner top packer/setting adapter to portion 344 . Torque dog 317 is also engaged and viewable through window 318 . In certain embodiments, the downhole tool 360 shown in FIG. 3A is run downhole and remains in the run in position until the desired wellbore depth is reached. In certain embodiments, the downhole tool 360 shown in FIG. 3A is prepared to place the liner top packer/setting adapter at a desired location downhole. FIG. 3B shows a first cross-sectional view of a downhole tool in a second position in accordance with embodiments disclosed herein. More specifically, FIG. 3B is a cross-sectional view taken through position B-B of downhole tool 360 after connection of the liner top packer/setting adapter. In some embodiments, FIG. 3B shows the clutch assembly after top clutch 313 has been engaged and the liner top packer/setting adapter is attached. FIG. 4A shows a downhole tool in a third position in accordance with embodiments disclosed herein. In FIG. 4A , downhole tool 460 is set to an extended position to prepare to release the liner top packer/setting adapter (not shown). In some embodiments, middle clutch 414 is engaged, effectuating rotational movement of portion 444 and more specifically, running nut 423 . An applied rotational force may thus cause running nut 423 to rotate to the right. In some embodiments, actuation of top clutch 413 prepares downhole tool 460 to be released from the liner top packer/setting adapter and subsequently pulled toward the surface of the wellbore (not shown). In certain embodiments, bottom clutch 416 cannot move because it is adjacent to the liner top packer/setting adapter. FIG. 4B shows a cross-sectional view of a downhole tool in a third position in accordance with embodiments disclosed herein. More specifically, FIG. 4B is a cross-sectional view taken through position B-B of downhole tool 460 . In some embodiments, FIG. 4B is a cross-sectional view of the clutch assembly after middle clutch 414 has been engaged. For example, FIG. 4B shows a view of the clutch assembly after the top clutch 413 has been engaged (and ready to compress torque dogs 417 ) to effectuate rotational movement of portion 444 , and more specifically, running nut 423 . FIG. 5 shows a downhole tool in a fourth position in accordance with embodiments disclosed herein. In some embodiments in FIG. 5 , liner top packer/setting adapter (not shown) is unthreaded in preparation to pull downhole tool 560 back to the wellbore surface. In certain embodiments, portion 544 , and more specifically, running nut 523 , is rotated to the right to disengage the liner top packer/setting adapter. In some embodiments, the rotation of running nut 523 releases downhole tool 560 from liner top packer/setting adapter and pulled back to the surface of the wellbore. FIG. 6 shows a downhole tool in a fourth position in accordance with embodiments disclosed herein. In some embodiments in FIG. 6 , a ball drop is performed to shear the shear screw 605 and ready downhole tool 660 to be rotationally disengaged from the liner top packer/setting adaptor and pulled back to the wellbore surface. In other embodiments, a ball drop is performed to shear the shear screw 605 and ready portion 644 to be released from the liner top packer/setting adapter by a rotational force on running nut 623 . In certain embodiments, hydraulic cylinder 607 may be pressurized using a ball drop method. In some embodiments, a ball drop within body 640 may increase fluid pressure to the piston, as explained below. The fourth position is functionally between the first and second position, described above. Different methods may be used to increase fluid pressure to actuate components of downhole tool 660 . In one embodiment, a method may include performing a ball (not shown) drop, including but not limited to, collet fingers, a ball valve, and a mechanically expanding ball seat. For example, downhole tool 660 may use collet fingers (not shown) as a ball seat, such that an expansion of the collet fingers may allow the ball to drop through the expanded seat. As another example, a rotating ball valve may be used such that a small hole in the valve acts as a seat for the ball and an increase in pressure causes rotation of the ball, allowing the ball to drop. As a further example, a ball drop method may include dropping a ball (not shown) from handling equipment at the wellbore surface (not shown) into one or more seats (not shown) within downhole tool 660 . In some embodiments, as the ball moves through the downhole tool 660 , it may cause fluid pressure to increase when seated. Upon application of pressure to the seated ball, one or more shear pins (for example, shear screw 605 ) may be sheared, thereby disengaging the downhole tool 660 from the liner top packer/setting adapter. In some embodiments, the shearing of the shear screw 605 and passage of fluid through the one or more ports may act upon one or more pistons (not shown) connected to top clutch 616 to disengage the torque dogs, thereby allowing transmission of rotational force to portion 644 , rotating running nut 623 and thereby releasing the liner top packer/setting adapter. Once the shear screw 605 is sheared, the ball may then be moved into a ball diverter (not shown), allowing fluids to be circulated through the downhole tool 660 , which is prepared for cementing steps. In some embodiments, hydraulic cylinder 607 may be pressurized to apply force to an actuator piston (not shown). Once the force exceeds a pre-determined set point, the piston may axially move the upper body 640 in order to shear the shear screw 605 . Advantageously, embodiments disclosed herein provide for an improved ability to mitigate tight spots and dog legs within the wellbore. Said another way, embodiments disclosed herein may advantageously allow an improved ability to wash and ream in the wellbore due to improved torque. In addition, some embodiments may advantageously use a bearing for rotation of the liner top packer/setting adaptor. Further advantages include the hydraulic mechanism of embodiments disclosed herein. Some embodiments disclosed herein may advantageously prevent premature release of the downhole tool by use of the hydraulic mechanism. Advantageously, in embodiments disclosed herein, the hydraulic mechanism may act as a hydraulic lock whereby premature release of the liner top packer/setting adaptor is prevented, thus providing improved reliability. Advantageously, embodiments disclosed herein provide an internal, flow path of a running nut, thereby allowing removal of debris from internal components of the downhole tool as the running nut is threaded and/or unthreaded. Further advantages include the improved alignment of the downhole tool with the liner top packer/setting adaptor provided by engagement of the one or more dogs. Also advantageously, embodiments of the present application may provide a timing feature, such that, for example, eight turns of the body starts rotation of a bottom clutch, while, for example, four turns may be effectuated to engage top and middle clutches. Those of ordinary skill in the art will appreciate that the number of rotations required to engage and disengage top, middle, and bottom clutches may vary in accordance with specific design requirements. While embodiments of the invention have been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the embodiments as disclosed herein. Accordingly, the scope of embodiments of the invention should be limited only by the attached claims.
A downhole tool includes a body supported from a running string; and a releasing assembly for releasing from set liner hanger portions of the tool to be retrieved to the surface. The releasing assembly includes a connecting member for engaging the tool with a liner hanger, a piston hydraulically moveable in response to fluid pressure within the tool body from a lock position to a release position for releasing the connecting member, and a clutch for rotationally releasing the tool body from the liner hanger. Rotation of the running string moves a nut upward along the body so that the running string may then be picked up to disengage the tool from the liner hanger.
4
CROSS-REFERENCE TO PENDING APPLICATIONS The present application is a divisional application of co-pending U.S. patent application Ser. No. 10/701,253, entitled “A Surgical Instrument for Treating Female Urinary Stress Incontinence,” filed Nov. 4, 2003, which is incorporated by reference herein. The present application claims priority benefits to U.S. patent application Ser. No. 10/701,253 under 35 U.S.C. §121. U.S. patent application Ser. No. 10/701,253 is a continuation-in-part application of U.S. patent application Ser. No. 10/308,735, which issued on Oct. 26, 2004 as U.S. Pat. No. 6,808,486, entitled “Surgical Instrument For Treating Female Urinary Stress Incontinence.” TECHNICAL FIELD OF THE INVENTION The present invention relates to surgical instruments for treating female urinary stress incontinence problems generally and in particular, a suburethral, anatomically configured mesh sling for implanting into the lower abdomen of a female which provides simultaneous support to mid-urethral and bladder neck sphincteric continence sites. BACKGROUND OF THE INVENTION The suburethral sling technique for treatment of stress urinary incontinence has become the preferred treatment because the long term results are better in most cases than other treatment methods. The classic pubovaginal sling technique utilizes rectus fascia from the patient as the sling material for support of the urethra. The morbidity of rectus fascia pubovaginal sling procedures has caused surgeons to utilize alternative materials. Permanent non-absorbable materials have been deployed in one such alternative but have resulted in erosions of the synthetic material into the urethra and vagina. Also, infections of the sling have had serious complications because of the material being treated as a “foreign body”. Cadaveric tissue has been used in an effort to avoid the problem of “foreign body” reactions resulting in infections and erosions. However, cadaveric fascia and cadaveric dermis have not had the same results as tissue derived from the patient at the time of surgery. Cadaveric fascia is a tissue remodeling material. That is, the human body recognizes the tissue as a familiar material and biochemically breaks down the tissue and rebuilds it as its own tissue. Unfortunately, during the breaking down period of the cadaveric tissue, the tissue strength often fails rendering support of the urethra inadequate. Consequently, the urethra “falls” back down and the sling fails. Remodeling tissue needs to have additional strength during the time of remodeling in order to avoid failure of the material due to material weakness. Once remodeling has occurred, the tissue is strong enough to provide a good result for a long time. Biodegradable materials such as polylactate are available that are degraded by the body slowly over 18 months to 30 months. These materials can be made into a mesh to support the tissue remodeling materials through the period of remodeling. This leaves normal body tissue supporting the urethra that has resulted from the remodeling process. The biodegradable sling material such as polylactate is absorbed by the body and there is no “foreign body” to create erosions and infections. Deployment of the current sling devices utilize complicated sling transfer instruments that cannot be well controlled by the surgeon. This has resulted in serious complications including perforation of bowel as well as injury to major arteries and veins causing death in young women who are otherwise healthy having a simple surgical procedure. It is critical that the sling transfer instrument be simplified and better control of the instrument be provided to the surgeon. As the urethra prolapses or “falls down” resulting in loss of bladder control, the entire vaginal wall also prolapses or “falls down”. Current sling procedures do not provide any support for the anterior vaginal wall. One of the most common causes of re-operation after current sling procedures is a cystocele repair to repair the anterior vaginal prolapse that should progressively worsened after the sling placement. Current slings are not designed to repair the anterior vaginal wall at the same time the support of the urethra is done. A sling is needed that supports the entire functional urethra as well as the base of the bladder to prevent progression of vaginal prolapse. The normal woman when in the standing has the urethra in a position that the axis through the urethra is 15 degrees to 35 degrees off a true vertical position. The pubic bone has an axis of about 45 degrees off a true vertical position. This makes the angle or the axis of the pubis and the angle of the axis of the urethra about 70 degrees to 90 degrees. The base of the bladder as it attaches to the urethra has a posterior angle of 90 degrees to 115 degrees. The contoured sling is designed to restore the urethro-vesical angle and to restore the axis of the urethra. Deployment of contemporary sling devices utilize complicated sling transfer instruments that cannot be well controlled by the surgeon. This has resulted in serious complications including perforation of bowel as well as injury to major arteries and veins causing death in young women who are otherwise healthy having a simple surgical procedure. In keeping with the teachings of the instant invention, it is critical that a sling transfer instrument be simplified to allow enhanced instrument control by the surgeon. Given the deficiencies of the contemporary art and the enhancement teachings of the instant invention, it is an object of the instant invention to provide a tubular mesh sling for incontinence which eliminates urethral obstruction and voiding difficulties associated with slings and tapes of the contemporary art. It is another object of the instant invention to provide an incontinence solution which avoids the morbidity associated with rectus fascia tissue transplanted from the abdomen to the vagina of a patient and the long term durability deficiencies of cadaveric tissue as used in the contemporary art. It is a further object of the instant invention to provide an incontinence solution which avoids the numerous and serious complications from intra-operative injury to organs in the pelvis. It is yet another object of the instant invention to avoid paravaginal dissection required of surgical instruments and methodologies associated with the contemporary art. A further object of the instant invention is to provide an incontinence solution which is embodied as a sling design conforming to the anatomical variations of the urethra of women who have urinary incontinence. A yet further object of the instant invention is to provide a knit mesh pubovaginal sling which conforms to the anatomy of the urethra and anterior vaginal wall when the anatomy of a patient is distorted by urethral prolapse or previous vaginal surgery. Another object of the instant invention is to present a mesh sling embodiment in a component structure that has an anterior surface which attaches to the vaginal wall adjacent to the urethra and a posterior surface which attaches to the vaginal mucosa. An additional object of the instant invention is to provide an incontinence solution in a mesh sling form which avoids buckling due to opposing forces of the vaginal wall and vaginal mucosa on the sling. A further object of the instant invention is to provide a mesh sling which has an anterior and posterioral layer which provides greater tensile strength compared to tape mesh slings of the contemporary art. Yet another object of the instant invention is to provide a mesh sling design which demonstrates a significant degree of elasticity of the sling material. A further object of the instant invention is to provide a tubular mesh sling which embodies a dual continence design and can be positioned to support both the mid-urethra and bladder neck sphincteric continence sites. Another object of the instant invention is to provide a sling comprised in part of tissue remodeling material where sufficient support is provided to tissue remodeling material during biochemical breakdown of the tissue and rebuilding. Another object of the instant invention is to provide a sling which is comprised of biodegradable materials and tissue remodeling materials. A further object of the present invention is to disclose and teach a sling transfer instrument which allows enhanced sling deployment control by a surgeon. Another object of the instant invention is to teach a method and apparatus for sling deployment utilizing either suprapubic, transvaginal or obturator fossa deployment methodologies. A further object of the instant invention is an anterior vaginal sling that restores anatomical support to both the mid-urethral continence sphincteric function and the bladder neck continence sphincteric function. Another object of the instant invention is an anterior vaginal sling that restores the anatomical relationship of the urinary bladder to the urethral by providing confluent support to the base of the bladder and the proximal urethra. A further object of the instant invention includes an anterior vaginal sling that is contoured to restore the normal anatomical position of the mid-urethra, the proximal urethra, the bladder neck, and the base of the bladder which not only restores the normal continence sphincteric function of the urethra but also restores normal bladder function relative to the urethra. Yet another object of the invention provides an anterior vaginal sling composed of biodegradable mesh or non-biodegradable mesh in any non-proprietary weave configuration. An object of the instant invention provides an anterior vaginal sling design using biodegradable mesh reinforced tissue remodeling material with the biodegradable mesh combined with tissue remodeling material to provide tensile strength for the tissue remodeling material during an interval of tissue weakness due to the process of remodeling. The biodegradable material can be layered, stranded, or randomly combined with tissue remodeling materials. Still yet, another object of the instant invention provides a sling transfer instrument that has a progressively curved shaft portion and a sharply curved tip that allows the instrument to be passed through the retropubic space with a reduced risk of organ perforation. Further, an object of the instant invention provides the sling has supporting ribs throughout the distal part of each end of the sling to secure the sling to surrounding tissues and to allow for sling tension adjustment. Another object of the instant invention includes a biodegradable tab which is located at the middle of the sling and extends through the vaginal mucosa postoperatively to allow loosening of the sling tension postoperatively if necessary. A further object of the instant invention provides that the distal segment of each end of the sling is left in place postoperatively to allow tightening of sling tension if necessary. An attachable handle is used postoperatively for sling tension adjustment. Yet another object of the present invention provides a spring design sling tension adjustment instrument that is used intra operatively to insure proper sling tension. A further object of the present invention provides an extended embodiment of the sling that is used to provide support to the proximal segment of the anterior vagina to support cystocele repair. An additional object of the present invention provide that the sling transfer instruments are designed with a luminous coating for easy identification during cystoscopy should perforation of the bladder occur. Another object of the present invention is to provide a sling transfer instrument with detachable insertion handle designed to provide maximum control to the surgeon of the instrument tip to avoid organ perforation. Finger grips and a specially designed thumb control feature of the handle provides accuracy of tip placement. An alternative object of the present invention provides that the embodiment of the sling transfer instrument design is used for placement from a suprapubic position through the prevesical space into the vagina. The sling is attached to the tip of the instrument and transferred to the suprapubic position. SUMMARY OF THE INVENTION The pubovaginal sling of the instant invention is a tubular layered sling configuration. A mesh comprised of a biodegradable polymer such as polylactate is placed around a layer of tissue remodeling material such as cadaveric fascia to form a tubular layered sling configuration. The biodegradable polymer segment of the sling provides tensile strength to the tissue remodeling material throughout the remodeling period until the remodeled tissue has achieved maximum tensile strength. After the remodeled tissue has formed, the biodegradable polymer will begin to lose tensile strength and disappear through biodegradation, leaving normal body tissue from the remodeled material in position to support the anterior vaginal wall and urethra without “falling down” during tissue remodeling when the remodeling material is weakened by the remodeling process of the body. The layered sling configuration can be constructed with the tissue remodeling material layered between two layers of biodegradable material in a tubular configuration. The tubular sling may be configured from multiple layers of a single biodegradable material or it can be configured using multiple layers of different biodegradable materials. Multiple layers of a single tissue remodeling material may be used or multiple layers of different remodeling materials may be used. An embodiment of the tubular layered sling configuration includes a central tubular configuration of biodegradable mesh surrounded by a tubular sling comprised of tissue remodeling material. An alternative embodiment includes a non-biodegradable tubular mesh sling that can be placed between layers of tissue remodeling materials. An alternative embodiment includes a tubular mesh sling that has a central segment that is non-biodegradable with a distal segment that is biodegradable. Finally, an essential embodiment of the tubular sling design includes tubular distal segments with a layered non-tubular central segment. The layered tubular sling configuration of the instant invention has a unique design that is contoured to the anatomical configuration of the mid-urethra, the proximal urethra, and the base of the bladder. The contoured sling restores the normal anatomical relationship between the urethra and the bladder. Restoring the normal anatomical relationship of the urethra to the urinary bladder results not only in urinary continence but also enables normal voiding to occur following the operative procedure. Urinary continence is only part of the desired surgical outcome, however normal voiding following surgery is equally important as urinary continence for surgical management of incontinence in women. Slings of the contemporary art are often represented as a “tape” sling and do not restore the normal anatomical relationship of the urinary bladder to the urethra. The contoured tubular sling is shaped to restore the normal anatomy of the urethra and the base of the bladder. The restoration of the normal anatomical position of the urethra relative to the urinary bladder is critical for normal voiding following incontinence surgery. One of the most common problems following incontinence surgery using tape slings is bladder obstruction due to an abnormal anatomical relationship between the bladder and the urethra. The contoured tubular sling avoids the anatomical obstruction from the current “tape” slings by providing support for the urethra and bladder with the normal anatomical contour. In the instant invention, the normal anatomical position is restored not only of the urethra but also the base of the bladder. The most critical objective that must be accomplished is restoration of the anatomical relationship between the urethra and the bladder in order for normal voiding to occur after surgery. Voiding dysfunctions including urinary frequency, urinary urgency, and nocturia are common problems after current sling procedures because the normal anatomical relationship between the urethra and the bladder is not restored. The focus of treatment of stress urinary incontinence in women has been the urethra alone with methods to support the urethra to prevent incontinence with coughing or sneezing. The anatomical relationship of the urethra to the bladder has not been maintained with “tape slings” and the result has been postoperative voiding dysfunctions. The contoured tubular sling provides support to the functional urethral which is the mid-urethra, the proximal urethra and the bladder neck. In addition, the contoured tubular sling provides support to the base of the bladder which prevents voiding dysfunctions in women following surgery. An alternative embodiment of the contoured tubular sling using the layered sling configuration design is “extended support” of the anterior vaginal wall to include the entire anterior vaginal wall. This “extended support” provides surgical management of cystocele repair in combination with incontinence surgery. The “extended support” design has eyelets for suture placement or tissue anchor placement to secure the vaginal support segment of the tubular sling in position. An alternative embodiment of the “extended support” design of the layered sling configuration includes segments of different size and shape that are required to support vaginal vault repair including cystocele repair, enterocele repair, and rectocele repair. The distal segments of the layered tubular sling configuration is approximately 1 centimeter in width and has small “ribs” that pass transversely through the sling to secure the sling in position. The “rib” design eliminates the need for the plastic sheath of current slings. The plastic sheath of current slings is difficult to remove and excess sling tension is often a complication of intra operative sheath removal. The sling tension is adjusted using a spring loaded sling tension adjustment device. The sling tension adjustment device is designed to avoid the problem of the sling being placed with too much tension around the urethra which results in urinary retention following surgery. During the surgical procedure, the sling is tightened until the spring is compressed and the sling tension device is closed which results in appropriate sling tension. The “confluent” sling transfer instrument is a unique design that is passed from the vagina through the retropubic space. The tip of the transfer instrument has a reverse curve shape that keeps the tip in immediate contact with the pubic bone during placement of the instrument which avoids injury to the bladder, adjacent bowel or major arteries and veins. The preferred shape of the confluent sling transfer instrument is square with rounded corners. Alternative embodiments include oval shape and rectangular shape. The diameter of the curvature of the instrument is approximately 23.5 cm with a radius of approximately 8 cm. The proximal 6 cm of the instrument is straight and inserts into a handle. The handle is detachable which allows the sling transfer instrument to be passed from a transvaginal position to the suprapubic area on both the right and left side. A transfer handle is attached on the tip of the instrument in the suprapubic area and the insertion handle is detached to allow attachment of the sling. This allows the sling transfer instrument to be inserted transvaginally and passed through the retropubic space, the tip in the suprapubic area is then controlled by an attachable transfer handle, the insertion handle is detached, the sling is attached to the base of the instrument where the insertion handle was located, and the sling transfer instrument is pulled through the retropubic space in a single pass with a confluent motion. Once the sling is positioned in the suprapubic position, the sling is cut near the tip and the sling transfer instrument is removed on both the right and left side. After the sling transfer instrument is passed through the retropubic space, cystoscopy is done to insure that the instrument did not inadvertently pass through the urinary bladder. Since it is difficult to see a gray colored metal transfer instrument on endoscopic examination of the bladder, the confluent sling transfer instrument is covered with a luminous material to allow it to be easily identified endoscopically. The “luminous” feature of the confluent sling transfer instrument reduces the risk of unrecognized bladder perforation by the sling transfer instrument because it can be seen more easily on endoscopic examination of the bladder. Such luminous materials include but are not limited to fluorescent dyes, paints and coatings. The handle of the instrument is a critical feature of control of the instrument by the surgeon. The insertion handle is critical in determining the retropubic path of the instrument during passing of the instrument. The handle used is the same design described previously which allows the surgeon to precisely guide the tip of the sling transfer instrument against the pubic bone through the retropubic space during placement of the instrument which prevents injury to bowel, bladder, and major arteries. The size and shape of the handle allow the surgeon to have maximum control of the reverse curve tip of the instrument which is positioned against the pubic bone at all times during placement which avoids injuries from the instrument. When the transvaginal approach to placement of the contoured design of the layered tubular sling configuration is done, the confluent sling transfer instrument is passed from the vagina through the retropubic space. The thumb control of the introducing handle is used to maintain the reverse curve tip of the confluent sling transfer instrument directly in contact with the pubic bone throughout the retropubic placement of the instrument. When the tip of the confluent transfer instrument exits the skin in the suprapubic area, the transfer handle is attached to the tip of the instrument and cystoscopy is performed to insure that the sling transfer instrument did not pass through the bladder. With the transfer handle on the tip of the confluent transfer instrument to stabilize the instrument in position, the thumb controlled introducing handle is disengaged from the proximal end of the instrument and removed. The sling attachment tip is placed on the proximal end of the instrument where the thumb control handle was located, and the transfer handle that has been placed on the distal tip of the instrument is used to pull the confluent sling transfer instrument through the retropubic space along with the sling attachment tip and the distal end of the sling. The sling tension adjustment spring device is placed between the sling and the anterior vaginal wall. When the spring is compressed, the sling adjustment device is removed. The excess sling length in the suprapubic area is cut at the skin level. In women who have complicated incontinence such as failed previous surgery, the excess sling is cut 3 cm above the skin level. An antibiotic dressing is used to cover the ends of the sling. At approximately three days following surgery, the dressing is removed and sling tension is adjusted. Sling tension is increased by placing the sling adjustment handles on the excess sling material in the suprapubic area and applying increased tension to the sling along the anterior vaginal wall. When sling tension has been adjusted to the desired level, the excess sling material is removed. When sling tension is too tight, the sling adjustment tab in the vagina is grasp with an instrument and the sling tension is reduced by applying downward tension. The sling tension postoperatively is adjusted based on the clinical ability of the patient to void. When ideal sling tension is achieved, the sling adjustment tab in the vagina is cut at the vaginal mucosa level. Also, the ends of the sling in the suprapubic area are cut at the skin level. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated herein by reference, and which constitute a part of this specification, illustrate certain embodiments of the invention and, together with the detailed description, serve to explain the principles of the present invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the design engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in this application to the details of construction and to the arrangement so the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. DESCRIPTION OF THE DRAWINGS FIGS. 1 through 1B illustrate the mesh sling of the instant invention distinguishing further its tubular mesh and tissue remodeling material components. FIGS. 2 through 2A illustrate the mesh sling of the instant invention wherein tubular mesh and tissue remodeling materials have been structured and presented in an alternative structural relationship than that disclosed in FIGS. 1 through 1B . FIG. 3 is an illustration of the tubular sling of the instant invention providing further details with respect to its anatomical contoured design. FIG. 3A is an illustration of the sling of FIG. 3 providing further detail with respect to the center most position of the tubular sling and its tissue remodeling material component. FIG. 4 is an illustration of the tubular sling of the instant invention as positioned to anatomically support mid-urethra and bladder neck sphincteric continence sites as well as the base of the bladder. FIGS. 5 through 5B are illustrations of the sling transfer instrument tool as used in transvaginal and suprapubic deployment methodologies. FIG. 6 is an illustration of sling transfer tool as used in obturator fossa deployment embodiments. FIGS. 7 and 8 illustrate alternative embodiments of the tubular sling of the instant invention as deployed in extended continence support applications. FIG. 9 is an illustration of the sling tension tab of the instant invention for decreasing tension providing further detail to allow for proper sling tension subsequent to deployment and positioning. FIG. 10 is an illustration of the sling tension adjustment handle of the instant invention for increasing tension providing further detail to allow for proper sling tension subsequent to deployment and positioning. DESCRIPTION OF THE PREFERRED EMBODIMENT While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides for inventive concepts capable of being embodied in a variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope of the instant invention. FIGS. 1 through 1B illustrate the mesh sling of the instant invention distinguishing further its tubular mesh and tissue remodeling material components. Turning now to FIG. 1 through 1B . In FIG. 1 it may be observed where the mesh sling is generally referred to as element 3 and is comprised of a generally central segment 5 and distal segments 7 and 8 . The central segment 5 of the tubular mesh sling 3 is approximately 2.5 cm wide and 4.0 cm long with a rapid taper over approximately 1.5 cm down to a size of 1.0 cm in width at distal ends 7 and 8 . Each distal section 7 and 8 may be covered with a circular plastic sheath which extends and overlaps in the central segment 5 . The plastic sheath(s) are removed at the end of the sling's deployment procedure. Though variable and appropriate dimensions may be had with respect to the sling of the instant invention, the sling's deployment is most effective when practiced at an approximate length of 60 cm and 4.0 cm central section to position and support the bladder neck sphincteric and mid-urethral sphincteric sites as well as support for the base of the bladder. FIG. 1B is a cross-sectional view of the sling of FIG. 1 illustrating relative positioning of tissue remodeling material 10 , the sling's center most portion and mesh portions 11 and 12 substantially surrounding/sandwiching to tissue remodeling portion 10 . Said tissue remodeling portion 10 and mesh portions 11 and 12 are bonded or otherwise fixedly attached to one another by surgical adhesive means or suturing means well known to skilled practitioners of the art. FIG. 1C illustrates a partial sectionalize view of the distal segments 7 or 8 wherein tubular mesh sections are again defined as elements 11 and 12 and substantially surround tissue remodeling material 10 . Various tissue remodeling materials may be used with respect to practicing the sling of the instant invention including homologous tissues and heterologous tissues. The mesh portions of the sling of the instant invention 11 and 12 are non-limitedly comprised of non-absorbable polymers, such as polypropylene, and possess a filament size of approximately 0.006 of an inch. Biodegradable mesh portions are non-limitedly, absorbable polymers, such as polylactate with a filament size of approximately 0.015 of an inch. To those skilled in the art it will become readily apparent that for rapidly absorbable bio-polymers a larger filament size can and should be practiced. As disclosed in the parent application, a combination of filament patterns may be used to represent the knit pattern such as but not limited to a simple knit, a complex knit, or woven pattern. The knit pattern may have seams or be seamless and with the size of the filaments dependent upon the clinical application may be simple knit, complex knit, or woven pattern and such knit patterns may have seams or be seamless. The size of the filament is dependent upon the clinical application and chemical composition of the knit. The center segment may be a non-absorbable material with absorbable distal segments which provides a permanent support around the urethra and bladder neck while the retro pubic segment is absorbable and disappears over time. FIGS. 2 through 2A illustrate a readily envisioned alternative embodiment of the instant invention wherein the center most section 5 has been replaced with an alternative positioning structure of mesh materials 11 and 12 and tissue remodeling material 10 . Stated succinctly, the mesh sling of FIGS. 2 and 2A comprises a center most position wherein tissue remodeling material 10 substantially surrounds and sandwiches mesh section 11 . Further clarification with respect to the non-limiting alternative embodiment illustrated in FIG. 2 will be presented in conjunction with discussion of FIG. 3A . FIG. 3 is an illustration of the tubular sling of the instant invention providing further details with respect to its anatomical contoured design. Turning now to FIG. 3 . In FIG. 3 it is seen where the tubular mesh distal sections 8 and 9 attach in a graduating manner to contoured sling center most section 5 wherein center most section 5 as disclosed in FIG. 3 is contoured to support both mid-urethral and bladder neck sphincteric continence sites as will be discussed further in association with FIG. 4 . FIG. 3 illustrates further the positional structuring of tubular mesh and tissue remodeling materials as discussed in association with FIGS. 1 through 1B . The normal anatomical relationship between the bladder and urethra is restored by additional support to the base of the bladder. FIG. 3A provides greater specificity and illustrates the positional structures of mesh and tissue remodeling material as presented in associated with discussion of FIGS. 2 and 2A wherein distal ends 8 and 9 are shown presenting a tubular mesh sector (innermost presentation not disclosed in FIG. 3A ) and where the center most section of the contoured sling 5 is illustrated as comprising tissue remodeling material 11 to sandwich or otherwise encase tubular mesh section at contoured sling section's 5 center most portion. The mesh of the center portion 5 may be composed of the same material as the distal segment 8 , 9 or the mesh material 5 may be different from 8 , 9 including, but not limited to, biodegradable material combined with non-biodegradable material. FIG. 4 is an illustration of the tubular sling of the instant invention as positioned to anatomically support mid-urethra and bladder neck sphincteric continence sites as well as the base of the bladder to restore the normal anatomical relationship of the bladder to the urethra. Turning now to FIG. 4 . In FIG. 4 it is observed where the contoured sling of the instant invention 5 is shown properly positioned to support bladder 20 and urethra 21 sphincteric continence sites respectively labeled 22 the mid-urethral continence site and 24 the bladder neck continence site. For purposes of full and enabling disclosure and ease of reference, FIG. 4 further provides detail with respect to the positioning of pubic bone 25 , vaginal wall 26 and vaginal mucosa 28 . FIGS. 5 through 5B will further illustrate and disclose the sling transfer instrument of the instant invention as well as its deployment methodologies with respect to transvaginal utilization. Turning now to FIGS. 5 through 5A . In FIGS. 5 through 5A it is seen where the sling transfer instrument defines in part a progressively curved shaft portion 51 positioned between distal 52 and proximal ends 53 . An attached handle 54 located at the shaft's proximal end 53 . The sling transfer instrument 50 , attached handle 54 further comprises a digit control accommodation 55 with said digit control accommodation dimensioned approximately 2.5 to 4.5 cm in length, 1.0 to 4.0 cm in width and approximately 1.5 cm in depth. The progressively curved shaft portion 51 of the sling transfer instrument has a diameter of about 3.5 mm to about 4.0 mm and a progressive curve with a maximum radius of approximately 5.1 cm. As can be seen in FIG. 5 , the distal end 52 of shaft portion 51 is oriented in a direction opposite that of said shaft's curved portion. The distal end of the shaft portion oriented in a direction opposite of the shaft's curved portion is referred to as shaft tip portion and is approximately 1.0 cm in length and approximately 4.0 mm in width at an end opposite the end with handle 54 attached to shaft end portion 53 . FIG. 5B further illustrates a distal end of sling 7 which illustrates a mesh portion comprised of non-absorbable polymers and filaments having a diameter from 0.002 inch to about 0.08 inch. Alternatively, the mesh sling distal portion 7 may be comprised of absorbable polymers and filaments with said filaments forming a mesh pattern having a diameter from about 0.12 inch to about 0.1 inch. As discussed in association with FIGS. 1 and 2 , the mesh sling is approximately 1.0 cm wide at proximal and distal ends (proximal end not illustrated in FIG. 5B ) and a center most portion approximately 2.5 cm in length and 1.5 cm to 3.0 cm at its widest and generally center most position. As an alternative to transvaginal and suprapubic deployment, an obturator fossa sling transfer instrument may be used for this particular type of deployment methodology. An example of the exaggerated curvature distinguishing sling transfer instruments used in association with transvaginal deployment (as illustrated in FIGS. 5 through 5B ), FIG. 6 illustrates the progressively curved portion of the obturator fossa deployment embodiment wherein the progressively curved shaft portion 51 has a diameter from about 3.0 mm to about 4.5 mm and a progressive curve with a maximum radius of approximately 5.0 cm. Distal portions of said shaft 52 and handle portion (not illustrated in FIG. 6 ) remain consistent with specifications disclosed in association with FIGS. 6 , 6 A, 10 and 11 of the parent application (Ser. No. 10/308,735). Returning now to FIGS. 5 through 5B wherein the invention's deployment methodology for transvaginal practice is disclosed. With respect to transvaginal deployment, a sling of the type disclosed in detail in association with either FIG. 1 or 2 is provided with the sling defining in part a tissue remodeling portion and a mesh section and contoured to the anatomical configuration of the mid-urethra, proximal urethra and base of the bladder. A sling transfer instrument 50 is next provided having a distal end 52 and a proximal end 53 with a progressively curved shaft portion 51 positioned between said distal 52 and proximal 53 ends with a detachable insertion handle 54 located at the instrument 50 proximal end 53 . The sling transfer instrument is positioned with the detachable insertion handle 54 grasped within the human hand and using the handle 54 , the instrument guides the distal tip portion 52 through the vaginal wall 60 behind the pubic bone 61 , through the abdominal wall 62 and exiting the abdominal wall 62 below the pubic hair line. The detachable insertion handle 54 is next disengaged from the proximal end 53 of the sling transfer tool 50 after the sling transfer handle 57 is attached to the sling shaft curved tip 52 . The distal end of sling 7 is next attached to the sling transfer's proximal end 53 . The handle so attached 57 is then positioned within the human hand and using said handle 57 , the sling transfer shaft is retrieved or otherwise pulled in a motion to motivate the sling 7 attached to the instrument's proximal end 53 through the vaginal wall 60 , behind the pubic bone 61 , through the tissues of the abdominal wall 62 , traversing the perforations made in the vaginal wall and abdominal wall made previously. A second sling instrument is then inserted on a portion of the body sufficiently distanced and positioned exactly on the opposite side of the body from the first sling transfer instrument with exact deployment steps completed to cause sling 7 to form a U-shape around mid-urethral and bladder neck sphincteric continence sites. Once so positioned, the sling is displaced from the sling transfer instrument subsequent to said sling proximal and distal end passage through the abdominal wall. Post position sling tension may be further accommodated via a sling tension measurement component that is discussed and disclosed in association with Parent application Ser. No. 10/308,735. With respect to obturator fossa deployment, the procedure as described in association with transvaginal deployment is utilized with distinctions limited to the utilization of a progressively curved sling transfer instrument, as discussed in association with FIG. 6 , and an exiting of sling transfer instrument tip 53 at a point allowing the tip 53 to exit through the obturator canal near the labia majora of the vagina instead of the suprapubic position. With respect to the suprapubic method for treating urinary stress incontinence, a sling defining in part a tissue remodeling portion and a mesh section contoured to the anatomical configuration of the mid-urethra, proximal urethra and base of the bladder is provided. Said sling consistent with discussion and disclosure previously described in association with FIGS. 1 and 2 . A sling transfer instrument having a distal end and a proximal end with a progressively curved portion positioned between said distal and proximal ends with an insertion handle is located at the instrument's proximal end. The sling transfer's insertion handle is positioned with a human hand and utilizing the handle, guides a curved tip at the instrument's distal end through the abdominal wall, through the retro pubic space allowing the tip of the instrument to maintain contact with the posterior surface of the pubic bone as it traverses the retro pubic space and continues into the vagina. A second sling instrument is next provided and similarly traverses through the abdominal wall, through the retro pubic space allowing the tip of the instrument to maintain contact with the posterior surface of the pubic bone as it traverses the retro pubic space as it continues into the vagina. The second instrument so deployed is positioned and deployed in a manner to allow attaching of the sling described in the parent application (Ser. No. 10/308,735) to be attached to the distal ends of the sling instruments so deployed. Cystoscopy is performed subsequent to the tip of both instruments being positioned in the vagina. Having attached the sling to the distal ends of both instruments, both instruments are withdrawn or otherwise positioned in such a manner to allow the distal ends of the sling transfer instruments to cause the attached sling to form a U-shape around the mid-urethral and bladder neck sphincteric continence sites. Once so positioned, the sling is displaced from both sling transfer instruments and sling tension adjustment may be facilitated by a sling tension measurement component as deemed necessary. FIGS. 7 and 8 illustrate alternative embodiments of the tubular sling of the instant invention as deployed in extended continence support applications. FIG. 9 is an illustration of the sling tension tab of the instant invention providing further detail to allow for proper sling tension subsequent to deployment and positioning. FIG. 10 is an illustration of the sling tension adjustment handle of the instant invention for increasing tension providing further detail to allow for proper sling tension subsequent to deployment and positioning. The claims and specifications describe the invention presented and the terms that are employed in the claims draw their meaning from the use of such terms in the specification. The same terms employed in the prior art may be broader in meaning than specifically employed herein. Whenever there is a question between the broader definition of such terms used in the prior art and the more specific use of the terms herein, the more specific meaning is meant. While this invention has been described to illustrative embodiments, this description is not to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments as well as other embodiments will be apparent to those skilled in the art upon referencing this disclosure. It is therefore intended that this disclosure encompass any such modifications or embodiments. It will of course be understood that various changes may be made in form, details, arrangement and proportions of the apparatus without departing from the scope of the invention, which generally stated consists of an apparatus capable of carrying out the objects above set forth, in the parts and combination of parts as disclosed and defined in the appended claims.
A suburethral sling device and method for treating female urinary stress incontinence which is anatomically configured to implant into the lower abdomen of a female in a manner providing support to mid-urethral and bladder neck sphincteric continence sites with the sling defining in part, mesh and tissue remodeling portions. The sling is deployed via a sling transfer instrument having distal and proximal ends with the instrument comprising in part a progressively curved shaft portion positioned between the distal and proximal ends. An insertion handle of the transfer instrument is secured to the curved metal shaft section guiding the shaft tip through the tissues of the abdomen in an anterior/posterior direction as well as a cephalad/caudad direction.
0
This application is a continuation-in-part of application Ser. No. 08/339,336 filed Nov. 14, 1994, now U.S. Pat. No. 5,597,650, and a continuation-in-part of application Ser. No. 08/523,470 filed Sep. 5, 1995, now U.S. Pat. No. 5,620,797. FIELD OF THE INVENTION The invention relates to a carpet face yarn made of synthetic materials. BACKGROUND Carpets, rugs and mats for home and industrial use are typically made from synthetic or natural fibers such as nylon, polyester, polyolefins, acrylics, rayon, cellulose acetate, cotton and wool. Of the foregoing, synthetic fibers tend to be more commercially acceptable and can be used for a wider variety of applications. Of the synthetic fibers, nylon has been the polymer of choice for carpets. However, nylon is not without its drawbacks. Notably, nylon carpeting is susceptible to developing static electric charges and thus must be chemically or physically treated to reduce the buildup of static charges. Another disadvantage of nylon carpeting is that it will readily stain. Accordingly, nylon carpets usually contain treatments which reduce their staining tendencies. These treatments do not, however, prevent all staining, nor do they last for the life of the carpet. On the other hand, carpets made from polyolefins, such as polypropylene, are very resistant to staining and are naturally antistatic. However, polypropylene is a less resilient fiber and will not generally maintain its appearance or shape under prolonged or heavy use, or after repeated deformations. An object of the invention therefore is to provide an improved carpet face filament made of synthetic materials, and a method of making the same. Another object of the invention is to provide a carpet face filament of the character described having good resiliency with the stain resistance of polyolefins. Still another object of the invention is provide a method for producing a synthetic carpet face filament which exhibits inherent antistatic properties. A further object of the invention is to provide a synthetic carpet face filament of the character described which exhibits good dyeability and color fastness. Yet another object of the invention is to provide a synthetic carpet face filament which is economical to manufacture using conventional filament production processes. Another object of the invention is to provide a method for dying the synthetic carpet face yarn of the invention. SUMMARY OF THE INVENTION With regard to the above and other objects, the invention provides a synthetic carpet face yarn comprising substantially continuous filaments having a size ranging from about 12 to about 25 denier per filament wherein the filaments comprise from about 60 to about 95% by weight polyolefin, preferably polypropylene, as a continuous matrix and from about 5 to about 40% by weight of elongate generally longitudinally dispersed relatively small, short polymer fibrils inside the filaments generally concentrated toward the center thereof within the polyolefin matrix, wherein the polymer fibrils are selected from the group consisting of polyamide and polyester fibrils. Another aspect of the invention provides a method for making fiber for a carpet face yarn having improved stain resistance and resiliency. The method comprises conducting a mixture comprising from about 5 to about 40% by weight of a fibril-forming polymer selected from the group consisting of polyamide and polyester with from about 60 to about 95% by weight polyolefin through a hot melt extruder to produce a substantially homogeneous molten mixture which is forced at a shear rate within the range of from about 1000 to about 5000 reciprocal seconds through a spinnerette containing a plurality of capillary openings to produce individual filaments, drawing and hot air texturizing the filaments at a temperature ranging from about 120° to about 130° C. to provide drawn and texturized filaments having a denier ranging from about 12 to about 25 and combining the drawn and texturized filaments to provide a synthetic carpet face yarn. It has been found that filaments made according to the invention have a substantially continuous polyolefin phase and a substantially discontinuous polyamide and/or polyester fibril phase interspersed in the polyolefin phase and concentrated toward the center of the filament which provides in a polyolefin-type carpet yarn what amounts to polyamide- and/or polyester-type properties in terms of resiliency and color fastness, but without the apparent characteristic drawbacks of the material forming the fibrils. That is, the yarn exhibits the excellent anti-staining properties of polyolefins and their favorable flame retardancy and anti-static properties, but does not matt to the degree seen in conventional polyolefin fibers. The yarn is also less costly to produce than many polyamide and polyester filaments, since polypropylene is about 60% cheaper per pound in the current market than polyamide and about 50% cheaper per pound than polyester. In addition to the foregoing properties, the yarn of the invention comprising polyolefin/polyester filaments has a matt finish thus reducing the need for the addition of fillers such as titanium dioxide to decrease the luster of the yarn as is required with conventional polyamide carpet yarns. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an illustration, not to scale, of a preferred spinnerette orifice configuration for producing the synthetic carpet filaments of the invention. FIGS. 2 and 3 are cross-sectional illustrations, not to scale, of the trilobal or delta filaments of the invention. DETAILED DESCRIPTION OF THE INVENTION The synthetic carpet yarn of the invention contains from about 60 to about 95% by weight of substantially continuous polyolefin filaments containing from about 5 to about 40% by weight of substantially co-linear, discontinuous polyamide and/or polyester fibrils interspersed in the filaments. Because the polyolefin and fibril-forming polymer are melt blended and forced through capillary openings as a molten blend, each of the resulting filaments contain essentially the same amount of polyolefin and fibril-forming polymer as in the blend. An important feature of the carpet face yarn of the invention containing polyamide and/or polyester fibrils is that it has the resiliency and flame retardance of polyamide yarns such as nylon 6 and nylon 66, yet has the stain resistance of polyolefin yarns such as polypropylene. Furthermore, the carpet face yarn of the invention is resistant to the formation of a static electric charge common to polyamide carpet yarns. The polyolefins which may be used to produce the carpet yarn of the invention include, but are not limited to, polyethylene, polypropylene, poly(1-butene), poly(3-methyl-1-butene), poly(4-methyl-1-pentene), and the like as well as combinations or mixtures of two or more of the foregoing. Of the foregoing polyolefins, polypropylene is particularly preferred. Bulk polypropylene suitable for making the yarn of the invention is available from Shell Chemical Company of Houston, Tex. under the trade name designations NRD5-1263 and 5E70. The fibril-forming polymer blended with the polyolefin to make the filaments may be selected from the group consisting of polyamide and polyester. Polyamide polymers which may be used include the condensation product of a dibasic acid and a diamine such as adipic acid and hexamethylene diamine (nylon 66), and the addition reaction products of monomers containing both an acid and an amine group in the molecule, such as the polymerization product of e-caprolactam to form polycaproamide (nylon 6). Higher analogs of nylon 6 and 66 may also be used. Of the foregoing, nylon 6 is the most preferred polyamide for use in forming the carpet face yarn of the invention. A suitable source of polyamide is the nylon 6 polymer available from BASF Corporation of Asheville, N.C. under the trade name designation Type 403. Polyester polymers which may be used to make the yarn of the invention include, but are not limited to, the polycondensation products of dicarboxylic acids or anhydrides with dihydric alcohols and mixtures of the polycondensation products. Dicarboxylic acids and anhydrides which may be reacted with the dihydric alcohols include the saturated or unsaturated fatty acids and anhydrides such as maleic, fumaric, phthalic and adipic acids and anhydrides. A particularly preferred dicarboxylic acid or anhydride is phthalic acid or anhydride. The dihydric alcohols which are reacted with the dicarboxylic acids or anhydrides to provide the polyester polymers include, but are not limited to, the alkylene glycols having from about 2 to about 10 carbon atoms. Preferred dihydric alcohols include ethylene glycol, propylene glycol, diethylene glycol, and dipropylene glycol. Particularly preferred polycondensation products of dicarboxylic acids or anhydrides and dihydric alcohols include polyethylene terephthalate, polybutylene terephthalate and polypropylene terephthalate. A suitable source of polyester polymer is the polyethylene terephthalate polymer available from Wellman Corporation of Johnsonville, S.C. under the trade name designation PERMACLEAR PET. Another source of polyester polymer which may be used is polybutylene terephthalate polymer available from BASF Corporation under the trade name ULTRADUR B 4500. In order to impart flame retardance to the carpet face yarn, one or both of the dicarboxylic acid or anhydride and dihydric alcohols used to make the polyester polymer may be halogenated. Halogens which may be used include chlorine, bromine, and fluorine. Halogenated polyester compounds prepared from the halogenated acids or alcohols may also be mixed with other well known halogenated and non-halogenated flame retardants if desired to further increase the flame retardancy of the carpet face yarn. It is preferred that the blend of polyolefin and fibril-forming polymer used to make the carpet face yarn contain from about 60 to about 95 wt. %, preferably from about 75 to about 85 wt. % polyolefin and from about 5 to about 40 wt. %, preferably from about 10 to about 20 wt. % fibril-forming polymer. The polyolefin and fibril-forming polymer may be combined in a variety of ways, however it is preferred to dry blend the components prior to feeding the blend to an extruder. In the alternative, each of the polyolefin and fibril-forming polymer components may be fed directly to the extruder in any order provided there is sufficient residence time in the extruder to assure essentially homogeneous mixing of the two components. It will be recognized that a preblended essentially homogeneous mixture of polyolefin and fibril-forming polymer may also be fed to an extruder. With respect to a polyester fibril-forming polymer, once combined, the mixture of polyolefin and polyester is melt-blended and extruded under pressure to provide an essentially homogeneous mixture of the two components. Pressures ranging from about 700 to about 2000 psia (about 4.8 MPa to about 13.8 MPa) are preferably used to obtain a homogeneous mixture of the components prior to extrusion. The molten mixture is forced from the extruder spinnerette at a temperature within the range of 240° to about 300° C. through a plurality of trilobal or delta capillary openings. The extruder temperature used is a function of the viscosity of the fibril-forming polymer in the blend. Where the fibril-forming polymer has a higher viscosity, higher extrusion temperatures should be used. For example, when using nylon 6 the extrusion temperature is preferably in the range of from about 240° to about 280° C. When using polyethylene terephthalate the extrusion temperature is preferably in the range of from about 260° to about 300° C. FIG. 1 illustrates a capillary opening 10 for use in producing the filaments of the present invention in a trilobal configuration conventionally used in making carpet yarn. The capillary opening 10 has legs 12 of substantially equal length so that the melted mixture flows through the capillary opening 10 in legs 12 thereby increasing the shear rate on the molten mixture and causing the filament to set in a generally trilobal cross-sectional configuration 14 as illustrated in FIG. 2 or a delta cross-sectional configuration 16 as illustrated in FIG. 3. In FIGS. 2 and 3, the polyolefin 18 provides the bulk of the filament with elongate, longitudinally oriented polyamide or polyester fibrils 20 dispersed within the filament, generally concentrated toward the center of the filament. The shear rate of the molten mixture during extrusion is an important factor in practicing the present invention for optimal results. Shear rates in the range of from about 1000 to about 5000 reciprocal seconds are preferred. Particularly preferred is a shear rate within the range of from about 2000 to about 4000 reciprocal seconds, with a shear rate of from about 2500 to about 3800 reciprocal seconds being especially preferred. By selecting a plurality of capillary openings of an appropriate size having a trilobal arrangement, the desired shear rate for extrusion of the mixture may be obtained. After spinning, the filaments are drawn one or more times, preferably three times, and then texturized with either a hot air jet or a steam jet. Unlike other polymeric materials, spinning, drawing and texturizing of the filaments in discrete batch operations are not required. Accordingly, the filaments of the invention may be spun, drawn and texturized essentially continuously without the need for an intermediate curing or a waiting period. In the alternative, an intermediate waiting period may be used between the spinning, drawing and/or texturizing steps. For purposes of obtaining colored carpet face yarns, the components which are combined to make the yarns of the invention may each contain pigments or chemical dyes, or the finished yarn may be dyed. Useful inorganic pigments include, but are not limited to, cadmium mercury, cadmium mercury orange, cadmium sulfide yellow, cadmium sulfoselenide, titanium dioxide, titanium yellow, titanium green, titanium blue, cobalt aluminate, manganese blue, manganese violet, ultramarine red, ultramarine blue, ultramarine violet, and the like. Organic pigments include, but are not limited to, permanent red 2B, perylene red, quinacridone red, diazo orange, diazo yellow, isoindolinone, hansa yellow, phthalocyanine green, phthalocyanine blue, quinacridone violet, doxazine violet, and the like. Chemical dyes include, but are not limited to, the mono- and disulfonated acid dyes, as well as triphenylmethane, pyrazolone, azine, nitro and quinoline dyes. When used, the pigment dyes may be predispersed in the polyolefin master batch before the polyolefin and fibril-forming polymer are extruded. Since pure polyolefin filaments cannot generally be dyed with chemical acid or basic dyes, pigment dyes are typically used to give the polyolefin its color in a process known as "solution dyeing". Solution dyeing results in a permanent color that is highly resistant to staining or fading due to UV light. However, in contrast to conventional polyolefin filaments, the filaments of the invention may be dyed with disperse dyes in addition to the pigment dyes, and once dyed, the filaments of the invention have been found to exhibit stain resistant properties similar to pure polyolefin filaments. When the fibril-forming polymer used with the polyolefin to make the filaments is a polyamide, it is preferred to use a mixture of an acid dye and a disperse dye to dye the filaments. The mixture of dyes may contain from 0 to about 50 percent disperse dye and from about 50 to about 100 percent acid dye. A particularly preferred dye is a mixture of about 50 percent by weight acid dye and about 50 percent by weight disperse dye. When the polymer used is polyester, a disperse dye is preferably used. Disperse dyes are generally used with a carrier fluid which is compatible with the particular dye. Suitable carrier fluids are known to those of ordinary skill in the art. The amount of dye in the carrier fluid used to color the filaments may range from about 0.15 to about 0.7 percent by weight of the dye and carrier fluid, preferably from about 0.2 to about 0.5 percent by weight of the dye and carrier fluid. In order to dye the filaments, the filaments are preferably first washed with hot water usually containing about 0.5 percent by weight of a base such as NaOH, KOH or NH 3 OH. The temperature of the hot water wash ranges from about 60° to about 80° C. and should be hot enough to remove any residual finish oils which may be on the filaments. After washing, the filaments are preferably dyed in a dye bath at about 90° to about 100° C. for about 15 minutes. The dye bath is typically operated at atmospheric pressure. A filament made of a polyolefin/polyester mixture may be dyed using from about 0.2 to about 0.6 percent by weight disperse dye at the same temperature and pressure or at a temperature ranging from about 115° to about 120° C. while maintaining the dye under a slight pressure. A particular advantage of the carpet yarn made from filaments of the invention is the synergistic flame retardancy of the yarn. Even though the filaments of the yarn may contain only about 15 wt. % non-halogenated fibril-forming polymer and no flame retardants, the yarns according to the invention may exhibit about 45 to about 75% increase in flame retardance relative to the flame retardance of pure polyolefin yarn. When desired, the polyolefin/polymer filaments of the invention may also contain flame retardants. Flame retardants suitable for use with one or both the components of the filaments include, but are not limited to, brominated polystyrene, hexabromocyclododecane, decabromodiphenyl oxide, ethylene-bis(tetrabromophthalimide), ethylene-bis(dibromonorborane dicarboximide), pentabromodiphenyl oxide, octabromodiphenyl oxide, decabromodiphenoxyethane, poly-dibromophenylene oxide, halogenated phosphate ester, tetrabromophthalic anhydride, bis(tribromophthalic anhydride), tetrabromobisphenol-A bis(2-hydroxyethyl ether), tetrabromobisphenol-A bis(2,3-dibromopropyl ether), dibromo-neopentyl glycol, tetradecabromodiphenoxy benzene, aluminum oxide trihydrated, antimony oxide, sodium antimonate, zinc borate, di-acrylate ester of tetrabromobisphenol-A, and the like. A preferred flame retardant system will generally contain a halogenated organic compound and a flame retardant synergist such as antimony oxide. The total amount of flame retardant in the yarn may range from about 5 to about 15 wt. % of the total weight of filament. At about 10 wt. % flame retardant, there is often about a 50% increase in flame retardancy as determined by the radiant panel flame retardancy test. While not desiring to be bound by theoretical considerations, it is believed that the properties of the carpet face yarn of the invention are due, at least in part, to the in-situ formation of elongated, substantially discontinuous polyamide and/or polyester fibrils in a continuous polyolefin phase. The in-situ fibril formation is believed to be promoted by the immiscibility of the components of the mixture with one another, and the shear forces exerted on the molten mixture as it is forced through the capillary openings of the spinnerette. During extrusion, the forming polymer fibrils concentrate in generally longitudinally aligned orientation toward the center of the capillary openings of the spinnerette where the shear forces are the least. As a result, the elongate fibrils are interspersed in a continuous polyolefin phase which is concentrated near the walls of the capillary openings of the spinnerette where the shear forces are the greatest. Polyamide and/or polyester fibrils which are produced by the shear forces associated with passage of the material through the capillary openings have a diameter in the range of a fraction of a micron to a few microns and a length of several tens of microns, whereas the overall cross-sectional length of each side of the trilobal or delta filaments containing the fibrils may range from about 1 to about 3 millimeters. Typically, the fibrils will have an average diameter of from about 0.5 to about 5 microns and an average length ranging from about 400 to about 600 microns. Through a phenomenon not fully understood, the polyolefin forms into a continuous phase providing a matrix encapsulating the polymer fibrils. The polymer fibrils provide reinforcing to the polyolefin matrix similar to reinforcing provided by fiberglass in a thermoplastic or thermoset resin. Accordingly, the polyamide and/or polyester fibrils which are more resilient than the polyolefin improve the resiliency of the yarn over conventional polyolefins making an excellent material for carpet face yarn. Another factor which is believed to contribute to the formation of fibrils in the center of the filament is the difference in the melt viscosity between the polyolefin and fibril-forming polymer phases. The generally lower polyolefin melt viscosity may cause the polyolefin to flow much more readily through the capillary opening at the walls of the opening where the shear rate is highest while the more viscous fibril-forming polymer concentrates into areas of the capillary opening away from the walls. For example, at a shear rate of 3800 reciprocal seconds, polypropylene has a melt viscosity of 240 poises at 280° C. at the capillary wall. The melt viscosity for the same temperature and shear rate for polyester having an intrinsic viscosity of 0.64 is 2600 poises and is 7800 poises for polyester having an intrinsic viscosity of 0.81 at 280° C. Accordingly, the ratio of fibril-forming polymer melt viscosity to polyolefin melt viscosity is preferably within the range of from about 10:1 to about 40:1 for producing the filaments of the invention containing polyester fibrils in a polyolefin matrix. At a shear rate of 2500 reciprocal seconds, polypropylene has a melt viscosity of 330 poises at 260° C. at the capillary wall. The melt viscosity for the same temperature and shear rate for nylon 6 having a relative viscosity of 2.4 is 700 poises and is 1160 poises for nylon 6 having a relative viscosity of 2.7. Accordingly, the ratio of fibril-forming polymer melt viscosity to polyolefin melt viscosity is preferably within the range of from about 2:1 to about 3:1 for producing filaments containing polyamide fibrils in a polyolefin matrix. While it is preferred to utilize polyolefin and fibril-forming polymer without additives other than flame retardants and dyes or pigments, it will be recognized that the carpet face yarn of the invention may contain any one or more additives selected from antioxidants, fillers, antistatic agents, melt processing aids, UV and thermal stabilizers, plasticizers, and the like. Stabilizers useful with the components used to produce the filaments of the invention include, but are not limited to, calcium powders, calcium stearate, phenols and hindered phenols, zinc oxide, aryl esters, hydroxybenzophenone, hydroxybenzotriazole and the like. Antioxidants may be selected from alkylated phenols and bisphenols, alkylidene-bisphenols, alkylidene-trisphenols, alkylidene polyphenols, thiophenols, dithio-bisphenols, dithio-trisphenols, thio-polyalkylated phenols, phenol condensation products, amines, dilauryl thiodipropionate, distearyl thiodipropionate, dimyristyl thiodipropionate, ditridecyl thiodipropionate, pentaerythritol tetrakis(β-lauryl thiopropionate), p-benzoquinone, 2,5-ditert-butylhydroquinone, and the like. Melt processing aids which may be used, particularly when no distributive mixing head is used with the extruder, include maleated polyolefins such as POLYBOND 3200 available from Uniroyal Chemicals of Middlebury, Conn. and EPOLENE E-43 available from Eastman Chemical Company of Kingsport, Tenn. As described above, it is preferred to use a distributive mixing head for mixing the polyolefin and fibril-forming polymer in the extruder. Various features and aspects of the invention will now be illustrated with reference to the following nonlimiting examples. In the following examples, an essentially homogeneous mixture of polyester and polyolefin were obtained in a 1.5 inch single screw multizone extruder operating at a pressure of about 1500 psia (about 10.3 MPa) and having a first zone temperature of about 255° C. A preferred method for obtaining a controlled melting of the polymers within a single screw extruder barrel is by the use of a DAVIS STANDARD BARRIER (DSB) mixing screw available from Davis Standard Corporation of Pawcatuck, Conn. as disclosed in U.S. Pat. No. 4,341,474 incorporated herein by reference as if fully set forth. In conjunction with the DSB mixing screw, it is preferred to use a distributive mixing head such as a Union Carbide Corporation (UCC) mixer available from Union Carbide Corporation of Danbury, Conn., or a cavity transfer mixer (CTM) as disclosed in U.S. Pat. Nos. 3,486,192 and 4,419,014 incorporated herein by reference as if fully set forth. A particularly preferred multi-zone extruder for obtaining sufficient control of the temperature in each of the heating zones of the extruder barrel is the THERMATIC single screw extruder available from Davis Standard Corporation as disclosed in U.S. Pat. No. 5,149,193 incorporated herein by reference as if fully set forth. EXAMPLE 1 A dry blend mixture of 15 wt. % polyethylene terephthalate chips having an intrinsic viscosity of 0.64 from Wellman Corporation of Johnsonville, S.C. and 85 wt. % polypropylene pellets having a melt index of 12 (NRD5-1263 from Shell Chemical Company of Houston, Tex.) were fed from a feed hopper directly into a 1.5 inch hot melt extruder wherein a homogenous molten mixture was obtained. No color concentrate was added to the molten mixture. The molten mixture was then pumped through a pack of screens to remove any particles greater than 20 microns. The screened mixture was pumped to a spinnerette having 72 trilobal capillary openings in order to provide polyolefin/polyester filaments. Each trilobal capillary had leg lengths of 0.0205 inch and leg widths of 0.008 inch. The extrusion rate was 0.278 pound per hour per hole at 280° C. thereby producing a shear rate of 3800 reciprocal seconds. Carpet yarn was spun from the filaments in a two-step process. The spinning was done using polyester extrusion conditions at 300 m/min. The trilobal filaments were spun at a denier of 4500 per 72 filaments (about an average of 62.5 denier per filament) at a melt temperature of 280° C. The yarns were then drawn three times at 115° C. and hot air jet texturized at 130° C. to provide filaments having a denier of 1500 per 72 filaments (about an average of 20.8 denier per filament). The relaxation ratio of the textured yarn was 0.71:1 and the drawn denier was targeted for 1500 denier with 72 filaments (20.8 denier per filament). EXAMPLE 2 A batch of 100 wt. % nylon 6 chips having a relative viscosity of 2.4 (Type 403 from BASF Corporation of Asheville, N.C.) were fed from a feed hopper directly into a 1.5 inch hot melt extruder. The pure nylon 6 batch was made to obtain a control sample of yarn for comparison of physical properties to the polyester and polypropylene mixtures. No color concentrate was added to the molten mixture. The molten nylon 6 was pumped through a pack of screens to remove any particles greater than 20 microns. The screened nylon 6 was fed to a spinnerette having 72 trilobal capillary openings in order to produce filaments. Each trilobal capillary had leg lengths of 0.0205 inch and leg widths of 0.008 inch. The extrusion rate was 0.278 pound per hour per hole at a temperature of 260° C. thereby producing a shear rate of 3800 reciprocal seconds. Carpet yarns were spun in a one-step process according to the procedure described in Example 1. EXAMPLE 3 A dry blend mixture of 10 wt. % polyethylene terephthalate chips having an intrinsic viscosity of 0.64 (Wellman Corporation) and 5 wt. % polybutylene terephthalate (ULTRADUR B 4500 from BASF Corporation) and 85 wt. % polypropylene pellets having a melt index of 12 (NRD5-1263 from Shell Chemical Company) were fed from a feed hopper directly into a 1.5 inch hot melt extruder wherein a homogeneous molten mixture was obtained. Processing conditions as described in Example 1 were used to produce a polyolefin/polyester filaments having 1500 denier per 72 filaments (about an average of 20.8 denier per filament). EXAMPLE 4 A dry blend mixture of 15 wt. % polyester flake having an intrinsic viscosity of 0.81 from Bartex Corporation of Charlotte, N.C. and 85 wt. % polypropylene pellets having a melt index of 12 (NRD5-1263 from Shell Chemical Company) were fed from a feed hopper directly into a 1.5 inch hot melt extruder wherein a homogenous molten mixture was obtained. The polyester flake was obtained from reclaimed polyester bottles. No color concentrate was added to the molten mixture. The molten mixture was then pumped through a pack of screens to remove any particles greater than 20 microns. The screened mixture was pumped to a spinnerette having 72 trilobal capillary openings in order to produce polyolefin/polyester filaments. Each trilobal capillary had leg lengths of 0.0205 inch and leg widths of 0.008 inch. The extrusion rate was 0.278 pound per hour per hole at 280° C. thereby producing a shear rate of 3800 reciprocal seconds. Carpet yarn was spun from the filaments in a two-step process. The spinning was done using polyester extrusion conditions at 300 m/min. The trilobal filaments were spun at a denier of 4500 per 72 filaments (about an average of 62.5 denier per filament) at a temperature of 280° C. The yarns were then drawn three times at 115° C. and hot air jet texturized at 130° C. to produce filaments having a denier of 1500 per 72 filaments (about an average of 20.8 denier per filament). The relaxation ratio of the textured yarn was 0.71:1 and the drawn denier was targeted for 1500 denier per 72 filaments. For all of the above examples, hot air shrinkage percentages were determined at 140° C. after 10 minutes measured under 0.02 gpd. comparisons of the yarns of Examples 1-4 are given in Table 1. TABLE 1______________________________________ Denier Elonga- (gms/ Tenacity tion Crimp ShrinkageDescription 9000 m) (gpd) (%) (%) (%)______________________________________100 wt. % 1480 2.1 46 2.14 14NRD5-1263 1517 2.3 50 2.95 24100 wt % Nylon 615 wt. % PET 1488 2.5 66 2.79 21(0.64 IV), 85 wt. %NRD5-126315 wt. % PET 1530 1.8 70 2.63 19(0.81 IV), 85 wt. %NRD5-126310 wt. % PET 1500 2.1 92 3.03 24(0.64 IV), 5 wt.%PBT, 85 wt. %NRD5-1263______________________________________ As compared to polypropylene without polyester reinforcement, the carpet yarn containing polyester fibrils had an increase in elongation, crimp, and fiber shrinkage. Surprisingly, the tenacity, crimp and fiber shrinkage of the polypropylene/polyester yarn were comparable to that of pure nylon yarn, while the elongation of the yarn of the invention was much higher. In order to test the characteristics of carpet made from the polyolefin/polyester carpet yarn, the 1500 denier filaments were two-ply twisted and heat set. The twisting was 4.50×4.50 tpi and the heat set was done on a SUPERBA stuffer box available from Superba, S.A. of Mulhouse, France at a tunnel temperature of 132° C. To make a carpet from the yarn of the invention the filaments were broadloom tufted in 34 ounce cut pile (1/8 gauge, 9 stitches per inch, 15/32 inch pile height) on a latex substrate with secondary backing. Floor rating, flame retardance, stain rate and static electricity generation were then measured on the carpet yarns of the invention and were compared to 100 wt. % polypropylene and 100 wt. % nylon carpets. The results are given in Table 2. TABLE 2______________________________________ Floor Floor Rating Radiant Panel Stain StaticDescription (CRI visual) (watts/cm.sup.2) Rate.sup.1 (KV)______________________________________100 wt. % NRD5-1263 1.8 0.22 5 1.3100 wt. % Nylon 6 3.0 0.63 1-2 4.115 wt. % PET (0.64 IV),85 wt. % NRD5-1263 2.7 0.34 4-5 1.115 wt. % PET (0.81 IV),85 wt. % NRD5-1263 2.5 0.32 4-5 1.5______________________________________ .sup.1 Stain Rate--American Association of Textile Colorists and Chemists (AATCC) GreyScale method for Staining and color change. As illustrated by the foregoing samples, the polypropylene/polyester carpets had a floor rating 39 to 50% higher than pure polypropylene carpet even though the yarn contained only 15 wt. % polyester. Likewise, carpet made of filaments according to the invention had a synergistic increase in flame retardancy over that of pure polypropylene in the absence of any added flame retardants as determined by the radiant panel test. Pure polyester carpet typically has a flame retardancy of about 0.45 to about 0.55 watts/cm 2 . In terms of flame spread, carpet made from the yarn of the invention passed the pill test 8 out of 8 times and the smoke density of the carpet was 300. The stain rate of the polypropylene/polyester carpet of the invention is comparable to that of pure polypropylene carpet and significantly better than that of pure nylon carpet. Static electricity generation was evaluated by the AATCC-134 method using neolite soles at 20% relative humidity at 70° F. The maximum threshold limit of static electricity for human comfort is 3.5 kilovolts. None of the carpet samples which were tested were treated for static dissipation using an antistatic finish or antistatic carbon fibers. As illustrated above, the 100 wt. % nylon sample had an unacceptably high static electricity generation, whereas all of the other samples were virtually static electricity free. Accordingly, polypropylene/polyester (PP/PET) filament yarns containing 15 wt. % PET fibrils according to the invention were significantly better than 100% polypropylene filament yarns (NRD5-1263) in terms of flame retardancy and resiliency and were comparable to the 100% polypropylene filament yarns in terms of static electricity generation. The PP/PET filament yarns were also found to be comparable to the 100% nylon 6 sample yarns in terms of flame retardance and resiliency. The dyeability of the polyolefin/polyester yarn of the invention as compared to 100 wt. % nylon 6 yarn is illustrated in the following examples. In these samples, yellow, red and blue disperse dyes were used at various concentrations for dyeing the yarns and acid dyes were used for dyeing the 100 wt. % nylon 6 yarns. The dyes and amounts of dyes used for dyeing the yarns are given in Table 3. TABLE 3______________________________________ Sample DyeSample Description No. (wt. %) Color.sup.1______________________________________100 wt. % Nylon 6 A1 0.25 Yellow #199 A2 1.00 Yellow #199 A3 0.25 Red A4 1.00 Red A5 0.25 Blue #324 A6 1.00 Blue #32415 wt. % PET (0.64 IV), 85 wt. % B1 0.25 Yellow #54NRD5-1263 B2 2.00 Yellow #54 B3 0.25 Yellow #64 B4 2.00 Yellow #64 B5 0.25 Red #60 B6 2.00 Red #60 B7 0.25 Blue #87 B8 2.00 Blue #87 B9 0.25 Blue #60 B10 2.00 Blue #6015 wt. % PET (0.81 IV), 85 wt. % C1 0.25 Yellow #54NRD5-1263 C2 2.00 Yellow #54 C3 0.25 Yellow #64 C4 2.00 Yellow #64 C5 0.25 Red #60 C6 2.00 Red #60 C7 0.25 Blue #87 C8 2.00 Blue #87 C9 0.25 Blue #60 C10 2.00 Blue #6010 wt. % PET (0.64 IV), 5 wt. % PBT D1 0.25 Yellow #54and 85 wt. % NRD5-1263 D2 2.00 Yellow #54 D3 0.25 Yellow #64 D4 2.00 Yellow #64 D5 0.25 Red #60 D6 2.00 Red #60 D7 0.25 Blue #87 D8 2.00 Blue #87 D9 0.25 Blue #60 D10 2.00 Blue #60______________________________________ .sup.1 Color--The acid dyes which were used are available from Crompton & Knowles of Gibralta, Pennsylvania. .sup.2 Color--The disperse dyes which were used are available from Crompton & Knowles of Gibralta, Pennsylvania. Analysis of the dyed samples of Table 3, indicated that the polyolefin/polyester yarns of the invention were readily disperse dyeable even without the use of carriers for the dyes. Conventionally, carriers are required in order to obtain deeper dye shades for disperse dyeing of polyester yarns. However, even without the use of carriers, the yarns of the invention obtained acceptable shades for yellow, red and blue disperse dyes. The color fastness of the dyed yarn samples of Table 3 were compared to the color fastness of 100 wt. % nylon yarn using a cold water bleed test, high humidity (H.H.) ozone fade, NO 2 gas fade and 40 hour xenon light fastness tests. The results are given in Table 4 and are based on the AATCC grey scale for staining and color change. TABLE 4__________________________________________________________________________ 1 Cycle 1 Cycle 107 Cold Water Bleed Test H.H. Ozone NO.sub.2 gas 40 Hrs. XenonSample No. acetate cotton nylon dacron orlon wool Fade Fade Light Fastness__________________________________________________________________________100 wt. % 1A 5 5 4-5 5 5 5 5 5 5Nylon 6 2A 4-5 4-5 3-4 5 5 4-5 5 5 5 3A 5 5 4 5 5 5 5 5 5 4A 5 5 3 5 5 4 5 5 5 5A 5 5 4 5 5 4-5 5 5 5 6A 4-5 4-5 3 5 5 4 5 5 515 wt. % PET (0.64 1B 5 5 5 5 5 5 5 5 5IV), 85 wt. % PP 2B 4-5 4-5 4-5 4-5 5 4-5 5 5 5NRD5-1263 3B 5 5 5 5 5 5 5 5 5 4B 4 4-5 4 4-5 4-5 4-5 5 5 5 5B 5 5 5 4 5 5 5 5 4-5 6B 4-5 5 4-5 5 5 5 5 5 4-5 7B 5 5 5 5 5 5 5 5 8B 5 5 4-5 5 5 5 5 5 4-5 9B 5 5 5 5 5 5 5 5 5 10B 5 5 5 5 5 5 5 5 515 wt. % PET (0.81 1C 5 5 5 5 5 5 5 5 5IV), 85 wt. % PP 2C 4-5 4-5 4-5 4-5 5 5 5 5 5NRD5-1263 3C 5 5 5 5 5 5 5 5 5 4C 4 4-5 4 4-5 5 4-5 5 5 5 5C 5 5 5 5 5 5 5 5 4 6C 4 4-5 4 4-5 5 4-5 5 5 5 7C 5 5 5 5 5 5 5 5 5 8C 4-5 5 4-5 5 5 5 5 5 5 5C 5 5 5 5 5 5 5 5 5 10C 5 5 5 5 5 5 5 5 510 wt. % PET (0.64 1D 4-5 5 4-5 5 5 5 5 5 5IV), 5 wt. % PBT 2D 4 4-5 4 4-5 5 4-5 5 5 5and 85 wt. % PP 3D 4-5 5 4-5 5 5 5 5 5 5NRD5-1263 4D 4 4-5 4 4-5 5 4-5 5 5 5 5D 5 5 5 5 5 5 5 5 4 6D 4-5 5 4-5 5 5 5 5 5 5 7D 5 5 5 5 5 5 5 5 5 8D 5 5 5 5 5 5 5 5 5 9D 5 5 5 5 5 5 5 5 5 10D 5 5 5 5 5 5 5 5 5__________________________________________________________________________ As illustrated by the above examples, the polyolefin/polyester yarns of the invention had equivalent color fastness to nylon 6 and slightly better cold water bleed. The nylon 6 yarns bled on nylon in the cold water bleed test while the yarns of the invention did not bleed on any fabric. The production of polyester fibrils within the polypropylene phase of the filaments was confined by observation of the filaments under a magnification of 400× using polarized light and the dimensions of the fibrils were assessed. The differences in fibril characteristics between high and low intrinsic viscosity polyester fibrils (Examples 1 and 3, respectively) are shown in the following Tables 5 and 6. TABLE 5______________________________________Smaller SizeFibrils Length (L) Diameter (D) Ratio (L/D)______________________________________Low Viscosity 68 3.8 18PET (0.64 IV)High Viscosity 38 3.0 13PET (0.81 IV)______________________________________ TABLE 6______________________________________Larger SizeFibrils Length (L) Diameter (D) Ratio (L/D)______________________________________Low Viscosity 790 2.0 395PET (0.64 IV)High Viscosity 410 1.6 256PET (0.81 IV)______________________________________ As illustrated in Tables 5 and 6, high viscosity PET (bottle reclaim grade) polyolefin/polyester filaments exhibit a fibril length which is generally about 45% less than that of lower viscosity PET-containing filaments. Likewise the diameters and L/D ratios of the higher viscosity PET-containing filaments are generally lower than that of lower viscosity PET-containing filaments. The polyolefin/polyester yarns of the invention have a naturally matt finish without the addition of fillers such as titanium dioxide whereas pure nylon face yarns have a shiny finish and require the addition of fillers to reduce the gloss of the carpet fibers. Since there is no need to add fillers to the yarn of the invention production costs for the yarn may be minimized. EXAMPLE 5 A dry blend mixture of 14 wt. % nylon 6 having a relative viscosity of 2.4 (Type 403 from BASF Corporation) and 86 wt. % polypropylene pellets having a melt index of 12 (5A72 from Shell Chemical Company) were fed from a feed hopper directly into a 21/2 inch hot melt extruder wherein a homogenous molten mixture was obtained. A beige polypropylene color concentrate under the trade name BEIGE 182 from Americhem of Cuyahoga Falls, Ohio, was added to the molten mixture for color. The molten mixture was then pumped through a pack of screens to remove any particles greater than 20 microns. The screened mixture was pumped to a spinnerette having a 40 trilobal capillary openings in order to form filaments. Each trilobal capillary had leg lengths of 0.0205 inch and leg widths of 0.008 inch. The extrusion rate was 0.625 pound per hour per hole at 260° C. thereby producing a shear rate of 2450 reciprocal seconds. Carpet yarn was spun from the filaments thus formed in a two-step process. The spinning was done using nylon 6 extrusion conditions at 320 m/min. The delta-shaped filaments were spun at a denier of 2175 per 40 filaments at a temperature of 258° C. The yarns were then drawn three times at 125° C. and hot air jet texturized at 130° C. The drawing was 2 ply to yield a textured, singles yarn having a denier of 1450 per 80 filaments. The relaxation ratio was 0.71:1 and the drawn denier was targeted for 1450 denier with 80 filaments. The physical properties of the two ply yarn are given in the following Table. TABLE 7______________________________________ Denier Tenacity Elongation CrimpDescription (gms/9000 m) (gpd) (%) (%)______________________________________100% SA72 1470 2.45 41 2.20100% PA6 1451 3.20 50 3.2110% PA6,90% SA72 1463 2.49 49 2.9215% PA6,85% SA72 1490 2.61 45 3.15______________________________________ In order to form a suitable carpet face yarn, the 1450 denier polyolefin/nylon (PP/N) filaments are two-ply twisted and heat set. Twisting of the filaments is at 4.50×4.50 tpi and the yarn may be heat set on a SUPERBA stuffer box at a tunnel temperature of 135° C. Once twisted and heat set, the yarn of the invention may be broadloom tufted in, for example, 34 ounce cut pile having 54 stitches and 15/32 inch pile height. Carpet thus formed from the foregoing fiber exhibits a Carpet Research Institute (CRI) floor rating much better than pure polypropylene yarn and generally comparable to that of pure nylon yarn. The carpet face yarn of the invention also exhibits an improved flame retardancy as determined, for example, by a Radiant Panel test. The flammability rating of carpet face yarn made from the foregoing PP/N filaments generally have a flammability rating close to that of pure nylon yarn even though the yarn of the invention may contain only about 15 wt. % of nylon. As compared to polypropylene without nylon reinforcement, the carpet yarn containing nylon fibrils also has an increase in tensile strength and fiber shrinkage. Accordingly, both the 10% and 15% PA6 containing filaments are better than 100% polypropylene (SA72) in terms of flame retardance and resiliency and the 15% PA6 containing filaments have a flame retardancy and a resiliency comparable to that of 100% PA6. EXAMPLE 6 A carpet face yarn was made using nylon 6 polymer having a relative viscosity of 43 under the trade name BASF-BS400 available from BASF Corporation. The polypropylene was a homopolymer having a number average molecular weight of about 300,000 and a nominal 20 melt flow index under the trade name 5E70 available from Shell Chemical Company. The nylon was dried overnight at 160° F. to a moisture content of 0.05 percent by weight and was melt blended with the polypropylene. The melt blended mixture of nylon and polypropylene was extruded through a 72 hole trilobal spinnerette having leg dimensions of 0.0205 inch long and 0.008 inch wide. The extrusion rate was 0.2756 pound per hour per hole at 262° C. For comparison purposes, mixtures of nylon and polypropylene were extruded through a 72 hole spinnerette having 0.009 of an inch diameter round holes at 300° to 305° C. and at a rate of 0.1365 pound per hour per hole. The physical characteristics of pure polypropylene yarn and the PP/N6 yarn produced with both the round capillary spinnerette and the trilobal spinnerette are given in the following table. TABLE 8______________________________________ Stress at Bulk 50% Exten- Breaking atRun Strain sion Strength 120°No. Components (gpd) (%) (gpd) (%) Filaments______________________________________1 100 wt. % PP.sup.1 0.47 387 1.85 6 2000 mpm 333 denier2 100 wt. % PP 1.88 50 1.90 13 300 mpm 4500 denier3 94 wt. % PP 0.82 3.25 1.60 5 2000 mpm.sup. 6 wt. % N6.sup.2 333 denier4 94 wt. % PP 1.95 52 1.97 20 300 mpm6 wt. % N6 4500 denier5 90 wt. % PP 1.89 61 1.92 22 300 mpm10 wt. % N6 4500 denier6 85 wt. % PP 1.89 50 1.91 23 300 mpm15 wt. % N6 4500 denier______________________________________ .sup.1 PP is polypropylene polymer using the trade name 5E70 available from Shell Chemical Company of Houston, Texas, having a number average molecular weight of about 300,000 and a nominal 20 melt flow index. .sup.2 N6 is nylon 6 polymer having a relative viscosity of 43 available from BASF Corporation of Asheville, North Carolina. In the foregoing example, runs 1 and 2 were conducted with 100 percent polypropylene. The polypropylene and PP/N6 filaments of runs 1 and 3 were made using the 0.009 inch round capillary holes at a temperature of 300°-305° C. at an extrusion rate of 0.1365 pound per hour. The polypropylene and PP/N6 filaments of runs 2, 4, 5 and 6 were made using the trilobal spinnerette at a temperature of 262° C. and an extrusion rate of 0.2756 pound per hour per hole. As shown in the foregoing table, the PP/N6 yarn made according to the invention exhibited substantially more bulk than either pure polypropylene yarn or the yarn made in Run 3 using round capillary openings and a higher temperature. Photomicrographs of cross-sections of the filaments of run 3 exhibited no evidence of the formation of microfibrils of nylon in the polypropylene phase when magnified 400 times under polarized light at 45°. In contrast, photomicrographs made of cross-sections of the filaments of run 5 showed the presence of microfibrils of nylon embedded in the polypropylene phase under the same magnification. Longitudinal photomicrographs of the filaments of run 5 magnified 100 times and 400 times also showed the presence of microfibrils embedded in the polypropylene phase whereas there was an absence of microfibrils in the filaments of run 3 as determined by longitudinal photomicrographs of the filaments. Dyeability tests were also conducted on the yarns of runs 3 and 4. Disperse Blue #60 dye was used to dye the yarn of runs 3 and 4. The yarn of run 3 dyed nonuniformly as compared to the yarn of run 4 containing the same amount of nylon. Having described and illustrated preferred embodiments of the invention, it will be appreciated that various modifications, rearrangements and substitutions made to the invention by those of ordinary skill are within the spirit and scope of the appended claims.
The specification describes a process of making a fiber for a carpet face yarn, the yarn being made of polyolefin/polymer filaments which contain a plurality of longitudinally dispersed relatively small, short polymer fibrils inside the filaments generally concentrated toward the center thereof within the polyolefm matrix. The yarn has the stain resistant properties of polyolefm based yarns and the resiliency of polyamide based yarns at a substantially lower cost than nylon carpet yarns.
3
BACKGROUND OF THE INVENTION [0001] 1. Technical Field [0002] The present invention relates to a cleaning device of band-like apparatus for a paper machine being a paper manufacturing appliance, the band-like apparatus being used in a wire part, a press part and a dry part in a paper making stroke. [0003] 2. Background Art [0004] In general a paper manufacturing appliance, for example, a paper machine pours a pulp suspension being a raw material onto a wire belt and thereby performs a dehydrating process, transfers a sheet-shaped pulp fiber obtained by the dehydrating process onto a press belt in a press part, removes water contained in the pulp fiber through a pressing process and thereby produces a wet paper web. And in a dry part, it transfers the wet paper web obtained in the press part onto a canvas belt and further evaporates moisture therein. [0005] In such a paper making stroke, foreign materials are stuck on the surface of a band-like apparatus such as a wire belt, a press belt, a canvas belt and the like, namely, on the surface of a band-like cleaning object, and these foreign materials are generally natural resin or gum material extricated from wood, pulp, paper and the like, and further non-water-soluble adhesive materials having such organic matter as additive chemicals and the like used in a paper making stroke as the main ingredient. And these foreign materials are minute adhesive materials being present on a wet paper web in a dry part for example, and are made viscous by heating and stuck on the surface of a canvas belt or a roll. [0006] As a result, these adhesive materials receive pressure of paper, a dryer roll and the like from the surface of the canvas, come into and deposit in the inside of the canvas, and cause the degree of ventilation of the canvas to decrease. And the adhesive materials which have expanded and grown on the surface of the canvas adhere again or fall from the roll to the canvas and from the canvas to paper. As the result, there has been problems that stains or dents produced on the surface of the canvas cause breaking or defects of paper and cause the degradation in quality or productivity due to troubles such as deterioration in quality or in productivity caused by breaking of paper and the like. [0007] Thereupon, as disclosed in Japanese Patent Laid-Open Publication No. 5-504604 for example, there has been disclosed a method of providing an air blowing-off nozzle and a water jet device along a wire belt, blowing off an air flow against a band-like cleaning object from the nozzle, feeding water from the water jet device and thereby forming a water film on the inner face of wire, blowing away and sucking foreign materials through taking them in water by the air flow blown off from the air blowing-off nozzle, collecting the foreign materials in a hood and thus cleaning the wire belt. [0008] However, an air blowing-off nozzle needs to be arranged at a distance from the surface of a band-like cleaning object so as not to touch and damage the band-like cleaning object, and since a high-pressure cleaning fluid jetted from a water jet device exerts a large pressure on the band-like cleaning object, the water jet device and the cleaning object have needed to be arranged at a more distance from each other. [0009] As a result, a cleaning object and a device such as a nozzle or the like cannot be made close to each other, and in order to secure a certain cleaning capability the jet pressure to the cleaning object must be made high, and therefore the capability of the jet device has needed to be increased by increasing the jet pressure and the like. Due to this, the band-like cleaning object is liable to be damaged by a large jet pressure exerted on the band-like cleaning object, and since the band-like cleaning object needs to be more frequently replaced and the amount of cleaning fluid (air, water and the like) used is increased, there has been a problem that such a method leads to the increase in manufacturing cost and in running cost. [0010] Therefore, the present inventor has proposed a cleaning device arranging a cleaning fluid jetting nozzle inside a hollow rotating roll and cleaning a band-like cleaning object through an aperture for shower formed in the rotating roll from the jet nozzle. However, this cleaning device has only provided a plurality of apertures for shower at a certain pitches in the roll axis direction of the rotating roll along the roll rotating direction, but has not been made to completely clean away dirt such as foreign materials and the like from the band-like cleaning object by effectively utilizing the shape of an aperture for shower, a rotating roll and the like. As a result, it has been unsatisfactory from the viewpoint of the degree of cleaning of a band-like cleaning object. [0011] Thereupon, an object of the invention is to provide a cleaning device of a band-like apparatus, being made so as to clean away foreign materials before the foreign materials become huge on the surface of a band-like cleaning object without scattering the foreign materials around by improving a cleaning structure such as the shape of an aperture for shower and the like for the band-like cleaning object, in consideration of the above-described points. DISCLOSURE OF THE INVENTION [0012] In order to achieve the above-described object, the present invention is attained by a cleaning device of a band-like apparatus, comprising a hollow rotating roll being supported so as to be capable of turning along the traveling direction of the band-like apparatus and having a plurality of apertures for shower formed in it, and cleaning fluid jetting nozzles arranged at the inner side of the plurality of apertures for shower within an embracing angle of the band-like apparatus wound partially round the rotating roll, the cleaning device cleaning the band-like apparatus by jetting a cleaning fluid to the band-like apparatus from the cleaning fluid jetting nozzles, wherein the cleaning device comprises a plurality of blade plates being adjacent in parallel with the roll axis of the rotating roll in the traveling direction of the band-like apparatus and provides the plurality of blade plates and the rotating roll so as to be capable of freely reciprocating in the roll axis direction. [0013] And the above object is effectively attained by arranging a plurality of blade plates in parallel with the roll axis of the rotating roll and forming a plurality of projected portions and depressed portions at specified pitches at the contact side with the band-like apparatus in each of the blade plates. [0014] And the above object is effectively attained by forming projected and depressed portions at the contact side with the band-like apparatus in each blade plate. [0015] And the above object is effectively attained by using three blade plates and forming projected and depressed portions at blade projection pitches of 20 to 40 mm. [0016] And the above object is effectively attained by forming apertures for shower out of a plurality of long and narrow opening holes formed in the rotating roll and providing a plurality of slits formed so as to intersect the opening holes. [0017] And the above object is effectively attained by arranging three parallel slits in an inclined direction relative to the longitudinal direction of the apertures for shower as a plurality of slits. [0018] And the above object is effectively attained by making a plurality of slits cross one another in the shape of X relative to the longitudinal direction of the apertures for shower. [0019] And the above object is effectively attained by forming a band-like apparatus out of a roll for felt in a press part of a paper making stroke and setting the width of a slit in a range of 8 to 12 mm. [0020] Further, the above object is effectively attained by forming the band-like apparatus out of a roll for canvas in a dry part of a paper making stroke and setting the width of a slit in a range of 20 to 22 mm. BRIEF DESCRIPTION OF THE DRAWINGS [0021] FIG. 1 (A) is a schematic perspective view of a cleaning device of a band-like apparatus according to the present invention. [0022] FIG. 1 (B) is a sectional view taken along line X-X of FIG. 1 (A). [0023] FIG. 2 is a partially sectional view taken along the axial direction of a cleaning device of a band-like apparatus from which cleaning device a blade device is removed. [0024] FIG. 3 is a figure showing a plurality of apertures for shower formed in the surface of a rotating roll. [0025] FIG. 4 is a sectional view taken along line Y-Y of FIG. 3 . [0026] FIG. 5 is a graph showing the relation between the slit width of an aperture for shower and the degrees of cleaning and wear in a rotating roll for press of S 300 . [0027] FIG. 6 is a graph showing the relation between the slit width of an aperture for shower and the degrees of cleaning and wear in a rotating roll for press of S 400 . [0028] FIG. 7 is a graph showing the relation between the slit width of an aperture for shower and the degrees of cleaning and wear in a rotating roll for press of S 500 . [0029] FIG. 8 is a graph showing the relation between the slit width of an aperture for shower and the degrees of cleaning and wear in a rotating roll for press of S 600 . [0030] FIG. 9 is a graph showing the relation between the slit width of an aperture for shower and the degree of cleaning in a rotating roll for canvas of S 300 . [0031] FIG. 10 is a graph showing the relation between the slit width of an aperture for shower and the degree of cleaning in a rotating roll for canvas of S 400 . [0032] FIG. 11 is a graph showing the relation between the slit width of an aperture for shower and the degree of cleaning in a rotating roll for canvas of S 500 . [0033] FIG. 12 is a graph showing the relation between the slit width of an aperture for shower and the degree of cleaning in a rotating roll for canvas of S 600 . [0034] FIG. 13 is a graph showing the relation between the shape of a slit and the degree of cleaning. [0035] FIG. 14 is a figure showing the shape of a blade plate according to the invention. [0036] FIG. 15 is a front view of a blade plate being a variation example of the invention. [0037] FIG. 16 is a partial plan view of a rotating roll being a variation example of the invention. [0038] FIG. 17 is a partial plan view of a rotating roll being a variation example of the invention. [0039] FIG. 18 is a partial plan view of a rotating roll being a variation example of the invention. [0040] FIG. 19 is a graph showing the relation between the blade projection pitch and the degree of cleaning. [0041] FIG. 20 is a graph showing the relation between the blade projection pitch and the degree of cleaning. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0042] A band-like apparatus cleaning device according to the present invention is described in detail with reference to the drawings in the following. [0043] FIG. 1 (A), FIG. 1 (B) and FIG. 2 show a rough configuration of a band-like apparatus cleaning device 10 , and the band-like apparatus cleaning device 10 is mainly composed of a hollow rotating roll 21 , a cleaning fluid jetting device 31 , a sliding device 41 and a blade device 51 . This band-like apparatus cleaning device 10 is provided in each of a wire part, a press part and a dry part in a paper making stroke, and is made so as to clean away foreign materials such as an adhesive material, fiber and the like stuck on a band-like apparatus 11 such as a wire belt, a press belt, a canvas belt and the like. [0044] And as shown in FIG. 2 , the hollow rotating roll 21 supports a hollow supporting shaft 24 so as to be capable of freely turning by means of bearings 23 mounted on left and right sliding stands 42 of the sliding device 41 . And the hollow rotating roll 21 rotates in the traveling direction of the band-like apparatus 11 (direction of arrow in FIG. 1 (A)) in a state of having the band-like apparatus wound partially round the hollow rotating roll 21 , the band-like apparatus being given a specific tension, and has a number of apertures for shower 25 formed along the circumferential direction. At this time, the hollow rotating roll 21 is provided with a plurality of apertures for shower 25 formed along the roll rotating direction at certain pitches P in the axial direction of the roll. [0045] Hereupon, the hollow rotating roll 21 is provided with a cutwater ring 27 more inside (at the roll side) than the bearing 23 supporting the hollow supporting shaft 24 and thereby prevents lubricant of the bearing 23 and the like from being splashed over the band-like apparatus 11 wound partially round the hollow rotating roll 21 . [0046] Although the hollow rotating roll 21 may be forcibly driven, it may be turned being dragged by the band-like apparatus 11 moving in its traveling direction with a certain slippage relative to the band-like apparatus 11 . [0047] As a material for the hollow rotating roll 21 , special stainless steel is adopted, but any kind of materials being proof against a high-temperature and high-humidity environment in a dry part and being rich in corrosion resistance may be used. [0048] And the cleaning fluid jetting device 31 has a fixed roll 32 arranged so as to have a certain space inside the hollow rotating roll 21 and is fixed through a hollow supporting shaft 33 by a supporting stand 34 mounted on a sliding stand 42 of the sliding device 41 . A cleaning fluid jetting nozzles 35 is attached to the fixed roll 32 within an embracing angle of the band-like apparatus wound partially round the hollow rotating roll 21 and is arranged closely to and at the inner side of an aperture for shower 25 . [0049] In such a way, by arranging a cleaning fluid jetting nozzle closely to an aperture for shower 25 , it is possible to decrease a fluid jet pressure necessary for keeping a certain cleaning capability and also reduce the amount of cleaning fluid used. And Decrease of a fluid jet pressure prevents wear and clogging of a cleaning fluid jetting nozzle 35 and thereby makes it possible to prolong the life of the band-like apparatus cleaning device 10 . Further, in a cleaning fluid jetting device 31 at this time, nozzle groups 36 each being composed of a plurality of cleaning fluid jetting nozzles 35 are file-arranged along the longitudinal direction of each aperture for shower 25 (aperture group 26 ) at each pitch P corresponding to each aperture for shower 25 (aperture group 26 ) of the hollow rotating roll 21 in the roll axis direction of the hollow rotating roll 21 . [0050] And the cleaning fluid jetting device 31 inserts cleaning fluid jetting tubes 37 into the fixed roll 32 from an opening of the hollow supporting shaft 33 and connects cleaning fluid jetting heads 38 composed of square tubes and the like to these cleaning fluid jetting tubes 37 , and a plurality of cleaning fluid jetting nozzles 35 are connected in the longitudinal direction of the cleaning fluid jetting heads 38 . This cleaning fluid jetting head 38 extends from the left or right end of the fixed roll 32 to the middle part of the fixed roll 32 . And the fluid jet pressure from a cleaning fluid jetting nozzle 35 connected to each position in the longitudinal direction of each cleaning fluid jetting head 38 is made to be equal to each other in the longitudinal direction of each cleaning fluid jetting head 38 by reducing gradually the cross-sectional area of each cleaning fluid jetting nozzle 38 as being closer from the left or right end of the fixed roll 32 to the middle of the fixed roll 32 , and the like. [0051] And the sliding device 41 is made so as to mount a sliding stand 42 on guide rails 44 extending in the axial direction of the hollow rotating roll 21 , the rails being provided on a stand 43 and let this sliding stand 42 support the hollow rotating roll 21 and the cleaning fluid jetting device 31 . This sliding device 41 is made so as to screw-engage a feed screw 46 to be driven by a motor 45 supported by the stand 43 with the sliding stand 42 and make the hollow rotating roll 21 and the cleaning fluid jetting device 31 reciprocate within a range exceeding the pitch P of the aperture group 26 and nozzle group 36 as one body in the roll axis direction of the hollow rotating roll 21 by turning the motor 45 forward and backward. [0052] And as shown in FIG. 3 , an aperture for shower 25 of the hollow rotating roll 21 is formed into a long and narrow shape and two parallel slit portions 28 are provided so as to intersect the aperture for shower 25 . Since the slit portions 28 are pushed into the band-like apparatus 11 due to such shock as vibration or the like in a process in which the band-like apparatus 11 is traveling on the roll surface of the hollow rotating roll 21 , the band-like apparatus 11 comes to move in a zigzag direction. As a result, foreign materials which have come into the inside (minute gaps between warp and woof) of the band-like apparatus 11 result in, as shown in FIG. 4 , being rubbed and kneaded out by so-called rubbing and kneading action at point M and then being scraped away to the outside by so-called scraping-away action at point K. That is to say, thanks to these two actions (rubbing and kneading action and scraping-away action), the band-like apparatus 11 can extend gaps between warp and woof, collect foreign materials being about to come into the inside of the band-like apparatus 11 on the surface of the band-like apparatus 11 and thereby remove a more amount of foreign materials. [0053] Due to this, it is possible to improve the degree of ventilation of the band-like apparatus 11 , prolong the life of the band-like apparatus 11 , reduce a troublesome maintenance work by reducing the frequency of replacing periodically the band-like apparatus 11 , and reduce the labor cost and the running cost. And since the degree of ventilation is improved, it is possible to make the water of a wet paper web exhale sufficiently through meshes of the band-like apparatus 11 and increase the drying efficiency of paper. [0054] In this case, since when the width W of an aperture for shower 25 is made broader the band-like apparatus 11 comes to be more liable to move in a zigzag direction and more liable to receive a rubbing and kneading action and a scraping-away action, it is possible to remove more foreign materials from the surface of the band-like apparatus 11 . In the present invention, therefore, experiments were performed with regard to the relation between the aperture for shower 25 and the degree of cleaning. [0055] First, varying the diameter (face length) of a hollow rotating roll 21 , experiments were performed using rolls for press and canvas with regard to the relation between the slit width of an aperture for shower 25 and the degrees of cleaning and wear of a band-like apparatus. As a result, with regard to a roll for press, as shown in FIGS. 5 to 8 , it has been found that the degrees of cleaning and wear are the most preferable in comprehensive evaluation in case of 8 mm in slit width in S 300 , in case of 10 mm in slit width in S 400 , in case of 10 mm in slit width in S 500 , and in case of 12 mm in slit width in S 600 . On the other hand, with regard to a roll for canvas, as shown in FIGS. 9 to 12 , in consideration of the machining cost of the roll, it has been found that the degree of cleaning is the most preferable in case of 20 mm in slit width in S 300 and S 400 , and in case of 22 mm in slit width in S 500 and S 600 . In a word, from the viewpoint of degree of cleaning, it has been found that it is preferable to set the slit width in a range of 8 to 12 mm with regard to a roll for press and set the slit width in a range of 20 to 22 mm with regard to a roll for canvas. [0056] That is to say, the degree of cleaning was 11 hours and the degree of wear was 83% in case of 8 mm in slit width using S 300 with regard to a roll for press. And the degree of cleaning was 13 hours and the degree of wear was 79% in case of 10 mm in slit width using S 400 . And the degree of cleaning was 14 hours and the degree of wear was 81% in case of 10 mm in slit width using S 500 . And the degree of cleaning was 14 hours and the degree of wear was 79% in case of 12 mm in slit width using S 600 . On the other hand, with regard to a roll for canvas, the amount of adhesive foreign materials stuck therein being an index of the degree of cleaning was 540 g in case of 20 mm in slit width using S 300 , the amount of adhesive foreign materials stuck therein was 920 g in case of 20 mm in slit width using S 400 , the amount of adhesive foreign materials stuck therein was 750 g in case of 22 mm in slit width using S 500 , and the amount of adhesive foreign materials stuck therein was 550 g in case of 22 mm in slit width using S 600 . [0057] Hereupon, “S 300 ” is a band-like apparatus cleaning device of 314 mm in roll diameter and 1500 mm to 3400 mm in roll surface length, “S 400 ” is a band-like apparatus cleaning device of 400 mm in roll diameter and 3500 mm to 4900 mm in roll surface length, “S 500 ” is a band-like apparatus cleaning device of 500 mm in roll diameter and 5000 mm to 6200 mm in roll surface length, and “S 600 ” is a band-like apparatus cleaning device of 600 mm in roll diameter and 6300 mm to 7400 mm in roll surface length. [0058] Next, experiments with regard to the relation between the shape of a slit and the degree of cleaning were performed varying the slits in shape. As a result, as shown in FIG. 13 , an aperture for shower provided with three cross-shaped slits was the best in cleaning performance in S 300 , S 400 and S 600 , while an aperture for shower provided with three inclined slits was the best in cleaning performance in S 500 . [0059] By this, it is possible to jet a cleaning fluid jettingted from cleaning fluid jetting nozzles 35 connected to cleaning fluid jetting heads 38 at positions where the cleaning fluid jetting nozzles correspond to a nozzle group 36 to which the respective cleaning fluid jetting nozzles belong from apertures for shower 25 of the hollow rotating roll 21 to a band-like apparatus 11 by a cleaning fluid jetting device 31 , while making the cleaning fluid jetting device 31 and the hollow rotating roll 21 reciprocate as one body in the roll axis direction. [0060] Accordingly, it is possible to clean a band-like apparatus 11 over the whole width of it, and to make the steam being a cleaning fluid jetted from a cleaning fluid jetting device 31 remove and collect foreign materials from the inside of the band-like apparatus 11 on the surface of the band-like apparatus 11 . And since it is possible to clean the band-like apparatus 11 over the whole width of it and remove foreign materials, the moisture profile of paper is made stable. That is to say, no undried portion appears in a sheet of paper and paper being good in quality is obtained. [0061] And as shown in FIG. 1 (A), a blade device 51 is provided with two blade plates 52 , and a save-all 53 is provided under the blade plates 52 . Light fibers (paper powder) and the like are made to fall in the save-all 53 at the entrance side of a blade portion 54 but foreign materials stuck on the band-like apparatus 11 which have not been made to fall even by slit portions 28 of apertures for shower 25 of the hollow rotating roll 21 as described above are scraped away by the blade plates 52 . [0062] This blade device 51 scrapes away foreign materials stuck on the surface of the band-like apparatus 11 by pressing the edges 55 of the blade plates 52 against the surface of the band- like apparatus 11 at a certain pressure. The scraped-away foreign materials stay on the surface of the band-like apparatus 11 pressed by the edges 55 , adhere to one another at the back side of the edges 55 of the blades 52 , and expand and grow in the shape of a strip of paper. Therefore, it is possible to securely remove the foreign materials stuck on the surface of the band-like apparatus 11 without scattering them around. And the band-like apparatus 11 is not worn by the scraping of the blades 52 , and further the warp of the band-like apparatus 11 is not degraded in strength. [0063] As shown in FIG. 14 , the edge of a blade plate 52 has a shape capable of efficiently expanding and growing foreign materials into the shape of a strip of paper, namely, the two blade plates 52 A and 52 B have notches 56 A and 56 B corresponding to pitches P of the apertures for shower 25 of the hollow rotating roll 21 , and the two blade plates 52 A and 52 B are mounted so that these notches 56 A and 56 B are arranged alternately zigzag. [0064] Due to this, when a band-like apparatus cleaning device 10 operates, if it is a flat single plate having no notch, the whole device vibrates and a band-like apparatus 11 is made wavy and results in vibrating up and down in a process of carrying the band-like apparatus 11 , and parts where the band-like apparatus 11 comes into contact with and no contact with the blade plates 52 appear. As a result, parts from which foreign materials are scraped away and not scraped away by the blade plates 52 appear, but by providing such notches in the blade plates 52 , the band-like apparatus 11 is made to come into contact with the blade plates at locations 57 without fail. Therefore, by installing blade plates 52 so that notches 56 A and 56 B of the blade plates 52 A and 52 B are alternately arranged, it is possible to bring the blade plates 52 uniformly into contact with the whole surface of the band-like apparatus 11 . And by providing such notches in the blade plates 52 , it is possible to concentrate the actions of heat and contact pressure at the contact parts between the edges 55 of the blade plates 52 and the band-like apparatus 11 , efficiently expand and grow foreign materials, remove the expanded and grown foreign materials in a state where they are formed into a strip shape, collect the foreign materials in a state where they are scattered in the save-all 53 , and prevent a drainpipe of the save-all 53 from getting clogged. [0065] And a blade device 51 of a band-like apparatus cleaning device 10 according to the invention is not limited to the case of providing two blade plates 52 A and 52 B as described above, but may be provided with three blade plates 52 A′, 52 B′ and 52 C′ at specified pitches, as shown in FIG. 15 for example. That is to say, it is enough to provide a plurality of blade plates 52 so that they form a flat single plate having no notches when they are superposed one over another. [0066] And the shapes of apertures for shower 25 and slit portions 28 are not limited to the shapes as described above, but such shapes as the pitch, width and length of an aperture for shower 25 and the number of slits and the like may be determined depending on a kind of the band-like apparatus 11 and an embracing angle of the band-like apparatus 11 wound partially round the hollow rotating roll 21 , and the shape of them may be, for example, a shape where three slit portions 28 are provided perpendicularly to the longitudinal direction of an aperture for shower 25 as shown in FIG. 16 , a shape where three parallel slit portions 28 are provided at an inclined angle relative to the longitudinal direction of an aperture for shower 25 as shown in FIG. 17 , or a shape where slit portions 28 are crossed in the shape of X as shown in FIG. 18 , so that a rubbing and kneading action and a scraping-away action as described above efficiently exert on the band-like apparatus 11 . [0067] Thereupon, experiments were performed with regard to the relation between the blade projection pitch and the degree of cleaning, varying the number of blade plates 52 . As a result, as shown in FIG. 19 , the largest amount of foreign materials (about 1500 g) could be collected in case of using three blade plates and a blade projection pitch of 20 to 40 mm, preferably, 30 mm as shown in FIG. 19 . And the degree of cleaning was the most preferable in case of the blade projection pitch of 25 mm as shown in FIG. 20 . [0068] And since a band-like apparatus 11 can be cleaned uniformly over the whole width of it by providing a plurality of blade plates 52 provided with notches as described above to form a flat single plate having no notches when they are superposed one over another and further providing a flat blade plate, a flat blade plate having no notches may be provided. [0069] And although the present invention adopts stainless steel as a material for a blade plate 52 , any kind of materials being proof against a high-temperature and high-humidity environment in a dry part and being rich in corrosion resistance may be used. [0070] And in a band-like apparatus cleaning device 10 , a band-like apparatus 11 may be wound partially round a hollow rotating roll 21 setting a dirt-resistant surface of the band-like apparatus 11 as the inner face to be in contact with the hollow rotating roll 21 , and may be wound partially round the hollow rotating roll 21 setting a surface of the band-like apparatus 11 as the outer face of the band-like apparatus 11 to be in no contact with the hollow rotating roll 21 .
In order to provide a band-like apparatus cleaning device for removing foreign materials and cleaning a band-like apparatus before the foreign materials become huge on the surface of the band-like apparatus without scattering the foreign materials around by improving a cleaning structure such as the shape of an aperture for shower and the like for the band-like apparatus, there is provided a cleaning device of a band-like apparatus, comprising a hollow rotating roll being supported so as to be capable of turning along the traveling direction of the band-like apparatus and having a plurality of apertures for shower formed in it, and cleaning fluid jetting nozzles arranged at the inner side of the plurality of apertures for shower within an embracing angle of the band-like apparatus wound partially round the rotating roll, the cleaning device cleaning the band-like apparatus by jetting a cleaning fluid to the band-like apparatus from the cleaning fluid jetting nozzles, wherein the cleaning device comprises a plurality of blade plates being adjacent in parallel with the roll axis of the rotating roll in the traveling direction of the band-like apparatus and provides the plurality of blade plates and the rotating roll so as to be capable of freely reciprocating in the roll axis direction.
1
CROSS-REFERENCE TO RELATED APPLICATTONS Not Applicable STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not Applicable INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK Not Applicable REFERENCE TO A MICROFICHE APPENDIX Not Applicable BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to open-end spinning, i.e. rotor spinning. 2. Description of Related Art Open-end spinning frames normally consist of a series of individual spinning units, aligned on the two fronts of the machine, each of which consists of a spinning rotor, which produces heald yarn starting from the single fibers of a sliver and from a collecting unit which—after controlling the quality of the yarn by interposing a slit plate between the two components—leads the yarn to wind on a winding tube to produce a tapered bobbin. This tapered bobbin is formed by pulling and winding the yarn on its surface, as it is rotated by the underlying roll on which the bobbin in formation rests. The yarn is wound in cross-coils on the rotating tapered bobbin, as the collecting unit is equipped with a yarn carrier which distributes the yarn, by means of an axial backward-and-forward movement, on the external surface of the tapered bobbin. The structure of the individual spinning station is shown in the scheme of FIG. 1 , and its functioning is briefly described hereunder according to its normal operating conditions. Proceeding from below upwards, the spinning station 1 consists of the actual spinning unit 2 , and the collecting unit 3 , whose main components are briefly described hereunder, which transform the sliver with parallel fibres into yarn wound onto the tapered bobbin. The feeding sliver S is housed in a cylindrical container 4 where it is deposited in a double spiral. The sliver S is fed to the unit by a feeding roll 5 , passing through the funnel conveyor 6 and reaches the card 7 , a rotating roll equipped with a clothing which makes the fibres of the sliver S singular and sends them, by suction, to the spinning rotor 8 , which operates under depression. The singularised fibers are deposited, by centrifugal effect, on the peripheral throat of the spinning rotor 8 , which rotates at extremely high rates (up to 150,000 rev/minute and over); from here the fibers are collected and removed as a yarn F, axially leaving the central opening 9 , receiving torsions from the rotation of the rotor itself, during the run between its inner throat and said opening 9 , thus generating the twisted yarn F. The withdrawal of the yarn is effected by a pair of opposing extraction cylinders 11 and 12 , which seize the yarn F and operating at a controlled rate, according to the arrow a, thus determining the linear production of the yarn, normally expressed as m/min. The slit plate 14 for the control of the yarn F quality can be situated before the cylinders 11 / 12 . The yarn F thus produced enters the collecting unit 3 , passes through a sensor 15 detecting the presence of the yarn and reaches a compensator 16 to compensate the length variations of the distance between the spinning unit 2 and the deposition point of the yarn F on the tapered bobbin. The yarn-carrier device 21 distributes the yarn on the tapered bobbin by transversally moving with a backward-and-forward motion according to the double arrow b, driven by a motor 20 which operates a longitudinal rod 22 in common with the other units of the spinning frame. The tapered bobbin 25 collects the yarn F and is held by the bobbin-holder arm 26 equipped with two idle and openable counter-spikes 27 , which are connected to the base tube 28 of the tapered bobbin. The tapered bobbin in formation 25 rests against its operating roll or collecting cylinder 29 . The automatic open-end spinning frames of a recent design are equipped with service trolleys which inspect the front lines of the spinning frame and automatically effect the necessary interventions stopping in front of the spinning unit which requires them. There are essentially three types of required interventions: starting operation, at the beginning of the spinning, when the spinning frame is still, starting it and subsequently placing a new yarning tube in each station, the start-up being effected by re-attachment with an auxiliary yarn and winding the yarn produced on the new tube, to give a tapered bobbin, after eliminating the section of auxiliary yarn; re-attachment, when the yarn is interrupted for any reason, before reaching the envisaged length for completing the tapered bobbin, using the yarn already produced at the side of the tapered bobbin, effecting the re-attachment and restarting the winding on the same tapered bobbin. The re-attachment procedure consists, in its essential lines, in the opening, cleaning and closing of the rotor, in the preparation of the tail of the sliver, the capture and preparation of the end, at the side of the tapered bobbin, the re-starting of the rotor and feeding, the re-introduction in the rotor of the prepared end, the re-extraction of the end connected to the newly produced yarn, by winding it again in the collecting unit. The programmed cleaning cycle is equivalent to the re-attachment cycle, caused by a specific breakage of the yarn; collecting, after reaching the desired length to complete the tapered bobbin. The finished tapered bobbin is discharged and the unit is then restarted as specified above. These interventions of the controlling trolleys relate to both the collecting and starting or re-starting operations of the spinning station and to the repairing of yarn cuts due to natural causes or operated by the slit plates during the spinning. In general, these interventions are effected by separating the tapered bobbin 25 from its operating cylinder 29 , halting its movement and substituting the driving of the tapered bobbin 25 or its tube 28 by an auxiliary driving roll, positioned inside a service trolley. In the field of devices and intervention procedures of service trolleys in automated open-end spinning frames, the Applicant owns, among others, the recent European patent applications nr. 04077813.6, 04077814.4, 040778818.5, 04077819.3, as well as patents EP 340,863, EP 443,220, EP 473,212. Reference is made to these known technique references for greater details on the structure and functioning of these service trolleys. A device and re-attachment procedure for obtaining—in said transitory phases—a yarn having good mechanical and aesthetical characteristics, is described in the previous European patent application 04077818.5. For the sake of brevity, reference should be made to this document, in which the whole trolley is described in great detail with respect to its components. The intervention procedures carried out by service trolleys consist of a relevant number of phases effected from the trolley, interfacing it to the single unit or open-end spinning station with both its spinning rotor and overlying collecting unit, temporarily disconnecting these organs from their centralized driving units, and operating on the same with their own driving units, capable of bringing the spinning back to regime conditions, before re-activating the centralized commands and reconsigning the spinning unit to its normal centralized driving. In the open-end technology, the main problem of high quality tapered bobbin winding, derives from the fact that the open-end yarn is produced and delivered to the collecting unit intrinsically at a constant linear rate with a collecting system and that the yarn tension must in any case, also during transitory phases, be controlled and maintained within pre-established ranges. In a open-end spinning frame, the extraction rate of the yarn from the spinning rotor with extraction rolls or cylinders 11 , 12 , is strictly constant—apart from the short re-attachment transitory—as is also the collecting rate. Considering that the driving units are in common and centralized and that differences can exist between units, either as a result of different advancement degrees of the tapered bobbin during production, or due to small geometrical or set-up differences between the spinning units, the open-end machine normally operates with a slight predominance of the collecting rate with respect to the yarn extraction rate, exploiting the elasticity of the yarn, thus generating a certain “reeling” tension: this rate difference is an adjustable parameter of the machine according to the operative conditions and has a value of a few units per thousand. This expedient is due to the requirement that a loosening of the yarn downstream of the extraction rolls 11 , 12 is not acceptable, otherwise causing problems of yarn control and the impossibility of forming a tapered bobbin having the required characteristics for its use, downstream of the spinning process. Once the re-attachment has been successfully effected, the control and recovery phase of the yarn on the tapered bobbin 25 is of great importance, together with the re-consignment of the tapered bobbin itself from the auxiliary driving device situated in the service trolley to its normal driving roll 29 under regime conditions, which is part of the open-end spinning unit. BRIEF SUMMARY OF THE INVENTION The present invention relates to a trolley device which, during the re-attachment and collection cycles in the spinning start-up phase, generates a yarn reserve and provides this with a suitable tension for its new winding onto the tapered bobbin 25 . An objective of the present invention is to provide a yarn reserve which prevents risks of yarn tearing during the transitory phases, at the same time limiting to the utmost time wasting for the re-consignment of the tapered bobbin 25 to its roll 29 . In particular, the present invention improves the efficiency and duration of the intervention of the trolley, during the re-consignment phase of the tapered bobbin to the spinning unit, thus avoiding tearing of the yarn due to the imperfect alignment of the rate imparted to the tapered bobbin with the auxiliary roll of the trolley with that of the driving cylinder 29 . BRIEF DESCREPTION OF THE SEVERAL VIEWS OF THE DRAWINGS FIG. 1 is a diagram of an open-end spinning station showing the most important components. FIG. 2 shows a side view of a service trolley positioned in front of a spinning station of an open-end spinning machine. FIG. 3 is a side view of a service trolley which is engaged with a spinning station. FIG. 4 is a enlarged view of the sensors positioned in proximity with the yarn. DETAILED DESCRIPTION OF THE INVENTION To more clearly illustrate the problems faced and the technical solutions proposed with the present invention, reference is made, in the following description, to a trolley in which the device according to the invention is inserted and the process is effected for re-consigning the tapered bobbin to its normal functioning according to the present invention, at the service of an open-end spinning frame, for illustrative and non-limiting purposes. The device according to the invention is defined, in its main components, in the first claim, whereas its variations and preferred embodiments are specified and defined in the dependent claims. The process according to the invention is defined, in its essential steps, in the ninth claim, whereas its variations are specified and defined in the subsequent dependent claims. In order to present the characteristics and advantages of the present invention more clearly, the same is described with reference to its typical embodiment shown in the FIGS. 2 , 3 and 4 for illustrative and non-limiting purposes. FIG. 1 shows a scheme of an open-end spinning station with its most important components, in a typical embodiment according to a front view, and which must be served by the trolley according to the subsequent figures. FIG. 2 shows a service trolley C positioned in front of a spinning station of an open-end spinning frame, indicating the organs of the trolley C which intervene to effect the process according to the invention, as well as the device according to the invention for creating and handling a yarn reserve and providing it with the required tension for its re-winding onto the tapered bobbin 25 . The device according to the invention consists of a sucking mouthpiece 40 situated on the service trolley C, in which the shape and dimension of the yarn loop sucked inside, is controlled and determined. The particular characteristic of this sucking mouthpiece 40 consists of a series of sensors for detecting the presence of the yarn in its inside, so that the operating phases of the auxiliary roll 50 can be piloted, together with other parts of the service trolley, on the basis of the dimensions of the yarn loop sucked inside. In FIGS. 2 , 3 and 4 , the sensors are illustratively made up of pairs of elements, in which there is an optical sensor consisting of a source 41 S , 42 S and a receiver 41 R , 42 R respectively. The presence of the yarn is revealed when the reserve yarn F intercepts the optical path of the luminous signal emitted by the source 41 S and the receiver 41 R receives a reduced or disturbed signal with respect to the signal in the absence of yarn. The auxiliary roll 50 is equipped with known means for the rotational driving of the tapered bobbin 25 or the new tube 28 , according to a controlled clock/anticlockwise rotation to unwind/wind the yarn F during the service intervals, and it can be put in contact with the same, or moved aside, by moving its arm 51 forwards or backwards from the trolley C. The auxiliary roll 50 can be typically activated by means of a step-by-step motor piloted in frequency by the driving unit on the trolley. The interventions of the service trolley C are effected by lifting and releasing the tapered bobbin 25 from its normal operating cylinder 29 , and allowing the auxiliary roll 50 to take on the winding and unwinding operations, driven by the driving unit of the trolley. FIG. 2 shows the open-end spinning station subjected to the intervention of the trolley; the tapered bobbin 25 has been lifted from its normal operational roll 29 and has been put in contact with the auxiliary driving roll 50 on the part of the trolley. In FIG. 2 , the course of the yarn F from the rotor 8 to the tapered bobbin 25 is shown at the outlet of the spinning rotor 9 , through the slit plate 14 and the extraction rolls 11 , 12 . It then passes inside the yarn-presence sensor 15 and reaches an auxiliary yarn carrier 21 b is which substitutes the yarn carrier 21 during the intervention of the trolley C: more details can be obtained from the co-pending European patent application 04077819.3. During the intervention of said trolley C, the mouthpiece 40 is suitably moved closer to the run of the yarn F, in its tract between the extraction cylinders of rolls 11 , 12 and the yarn sensor 15 . In particular, the roll 11 has motorized driving, whereas the roll 12 is idle and is pressed against the roll 11 , which transmits rotation to the same. The approach and distancing means of the mouthpiece 40 can operate by rotation, for example according to the arrows d, and/or translation and are completely conventional. The mouthpiece 40 is connected to a depression generation system, which induces a significant sucking action therein. The configuration of the mouthpiece 40 is shown more evidently with respect to its terminal part, in its enlarged detail of FIG. 2 . It sucks in a certain amount of yarn F, whose value is measured by the yarn-presence sensors 41 , 42 : the yarn loops can have different dimensions, for example a minimum dimension shown as a dashed line, an intermediate dimension shown as a dash-point line, a greater dimension shown as a dotted line, as illustrated in the enlarged detail of FIG. 4 . The sucking mouthpiece 40 accumulates the available amount of yarn in its interior and, as a result of the suction effect, keeps it extended inside, exerting a tension thereon in direct proportion to the length of the sucked yarn. The mouthpiece releases the yarn F when the same is pulled back to be wound onto the tapered bobbin at a speed greater than that with which it is released from the rolls 11 , 12 , thus exhausting the reserve of yarn previously created. Again with reference to FIG. 2 , the re-attachment process of the yarn is as follows. The yarn F is pulled back, by means of the auxiliary roll 50 , unwinding a certain amount and forming a loop of yarn inside the mouthpiece 40 , shown by the dash-point line, whose minimum length can be measured by an inner pair of sensors 42 , so to ensure a sufficient tension on the yarn F and a suitable reserve, as shown in the enlarged detail. The dimension of the yarn reserve can also be enlarged, to operate with greater tranquillity, considering that the auxiliary roll 50 —according to a preferred variation of the embodiment of the present invention—is equipped with driving means for operating at substantially higher rates than those of the normal collection. After reattachment, the extraction rolls 11 , 12 extract the yarn F at a constant and pre-established rate. The tapered bobbin 25 is not yet in contact with its driving roll 29 , but is driven by means of the auxiliary roll 50 , which effects an acceleration to reach the closest possible rate to the standard collecting rate, subsequently returning the tapered bobbin to its normal operation. The yarn runs from the rotor 8 to the tapered bobbin 25 at a rate in the order of 200 meters per minute. A substantial yarn reserve is necessary at this point, to compensate a certain non-uniformity between the various spinning stations, avoiding tears. With a sucking mouthpiece without yarn-presence sensors and therefore lacking indication of the dimension of the loop in its interior, the recovery of this reserve would be left to the “reeling tension” alone, i.e. to the small difference in rate between extraction and collection. The recovery of a yarn reserve having the right dimension for a correct procedure can therefore require significant time during which the sucking mouthpiece is left in position, thus prolonging the time of each intervention of the trolley C and negatively affecting the overall service factor of the entire spinning frame. The procedure is completely different when the mouthpiece 40 is equipped with sensors. After re-attachment, the auxiliary roll 50 can be driven at a rate also considerably higher than the collection rate, so as to rapidly reduce the yarn reserve in the mouthpiece 40 and, regardless of the conditions in the single spinning unit, bring the rate of the tapered bobbin as close as possible to the collection rate. According to a preferred embodiment, this result is obtained by piloting, by means of the driving unit on the service trolley, the auxiliary roll 50 , as well as other parts of the service trolley, on the basis of the information supplied by the sensors 41 , 42 , . . . which are transmitted to the same driving unit for the processing of the relevant commands. In the recovery of the reserve and, more specifically, in its starting phase, until the innermost sensor 42 detects the presence of the yarn, i.e. the reserve yarn loop exceeds said sensor, the rate of the auxiliary roll 50 is preferably maintained considerably higher than the collection rate. When the innermost sensor 42 detects the disappearance of the yarn F, the amount of residual reserve is known, which allows the rate of the auxiliary roll 50 to re-coincide with the collection rate, within a known time, i.e. exactly when the outermost sensor 41 also detects the disappearance of the yarn F. At that moment all the parameters are known: the amount of reserve yarn, the rate of the auxiliary roll 50 , the rate of the cylinder 29 , the extraction rate of the rolls 11 , 12 . Once this last condition has been reached—rate under regime conditions and disappearance of the yarn from the sensor 41 —the reserve is at its minimum and the spinning station can be put in the condition of FIG. 3 . The tapered bobbin 25 is put back into contact with its driving cylinder 29 , the roll 50 has already moved away, the mouthpiece 40 is allowed to re-enter and the cycle of the trolley C, which can be removed, is terminated. The yarn reserve F is recovered, in its short residual tract, due to the “reeling tension”, i.e. the rate differential between extraction and collection; this recovery is effected in about one second. With reference to the course of the yarn F, the same is reconsigned to its normal yarn carrier 21 and restarts its normal traversing movement. In the exemplificative embodiment of FIGS. 2 and 3 , only two sensors are shown, for the sake of simplicity, an inner sensor 42 , which allows the recovery of the reserve by means of the auxiliary roll 50 activated at a high rate until it emits a yarn-presence signal, and an outer sensor 41 , which detects the minimum useful amount of yarn reserve, to mark the moment of reconsignment of the tapered bobbin 25 to its normal driving with the roll 29 , when it stops emitting the yarn-presence signal. More sensors can in fact be installed, for example three sensors—shown in the enlarged detail of FIG. 4 —for a greater regulation of the roll 50 rate during the recovery of the reserve and/or to obtain a certain tension effect on the sucked yarn, by operating on the driving of the auxiliary roll 50 , until the presence of the yarn F with a loop which protrudes from the inner sensor 43 is registered. As an alternative, resort can be made to a continuous reading system—for example with a television camera—to obtain a continuous measurement of the dimensions of the yarn reserve. The device according to the present invention has substantial advantages with respect to the devices of the known art. It allows the formation and control of a measured reserve of yarn F, giving it a controlled tension for its winding onto the tapered bobbin 25 during the transitory phases controlled from the trolley. The device according to the invention essentially consists of a sucking mouthpiece 40 positioned on the service trolley C, equipped with a series of sensors 41 , 42 , 43 for detecting the presence of the yarn, which emit yarn presence/absence signals to the control unit which drives the operating phases of the auxiliary roll 50 , modulating its rate according to the extent of the dimension of the reserve of yarn F. As far as the improvement in the trolley efficiency is concerned, the time economy is relevant, obtained in the reconsignment phase of the tapered bobbin to its operating, which is in the order of three-six seconds, thus shortening the intervention cycle by 15-25%. Greater security is also obtained with respect to yarn tears during the reconsignment of the tapered bobbin, which imply repetition of the entire intervention procedure, further lowering the service factor of the entire spinning frame.
Device for generating and controlling a yarn reserve to be installed on service trolleys with open-end spinning frames, for reattachment and start-up interventions on the spinning unit, comprising a mouthpiece which sucks and generates in its interior a loop of reserve yarn, equipped, inside, with sensors for detecting the dimension of the loop of reserve yarn and consequently piloting the reattachment procedure and reconsignment of the bobbin to its standard functioning.
3
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to PCT/NL2011/050165 filed Mar. 11, 2011, which claims priority to U.S. Application No. 61/313,531 filed Mar. 12, 2010 and Dutch Patent Application No. 1037800 filed Mar. 12, 2010, the entirety of each of which is incorporated by reference herein. TECHNICAL FIELD AND BACKGROUND The invention relates to a photo cathode for use in a vacuum tube at least comprising a cathode layer, having an entrance face capable for absorbing photons impinging on said cathode layer, and an exit face for releasing electrons upon impinging of said photons, as well as an electron exit layer, in facing relationship with said exit face of said photo cathode layer for improving said releasing of said electrons. The invention also relates to a vacuum tube with a photo cathode according to the invention. Please note that in this application vacuum tube structures comprise—amongst others—sealed devices like image intensifiers and photo multipliers that incorporate elements or subassemblies like discrete dynodes and microchannel plates that use the phenomenon of secondary emission as a gain mechanism. Such vacuum tubes are known in the art. They comprise a cathode which under the influence of incident radiation, such as light or X-rays or other elementary particles (electrons), emits electrons, like for example photo electrons, which move under the influence of an electric field towards an anode. The electrons striking the anode constitute an information signal, which signal is further processed by suitable processing means. Electron Affinity (EA) is a physical parameter and proposes the energy a free electron will loose when it is emitted from the cathode to the vacuum. The value of the electron affinity is determined, among others, by the material properties of the cathode. Most materials have a positive electron affinity and yield a very low quantum efficiency (QE), being the amount of electrons emitted to the vacuum per incident photon. Some other materials have a negative electron affinity (NEA). In materials with a NEA the electron gains energy upon entering the vacuum, therefore the chance of being emitted to the vacuum is fairly high and the QE of the NEA cathodes is much higher than that of cathodes with a positive electron affinity. These NEA cathodes are known in that art. As the QE is low, it can be improved by depositing an electron exit layer on the photo cathode layer, wherein the electron exit layer having a NEA. These depositions however have to be performed in ultra high vacuum and the bonding between III-V based cathode layer and the electron exit layer is based upon Van der Waals forces and therefore very weak. Some (namely III-V based) cathodes with NEA properties and comprising an electron exit layer have a high QE, typically around 40%. The drawback of the use of an electron exit layer however is that, because of the weak bond, the electron exit layer has to be protected from chemical attacks of gasses emitted by the microchannel plate positioned inside the vacuum chamber of the vacuum tube and the phosphor screen applied on most anodes. An other phenomenon to which the electron exit layer has to be protected is so-called ion feedback. This occurs when (negatively charged) electrons that have acquired sufficient kinetic energy in the accelerating electric field strike and ionise atoms or molecules still present in the vacuum or adsorbed at the surfaces stricken by the electrons. Once the neutral gas atom or molecule has been positively charged by the electron impact that knocked an electron from the outer region of the atom's electron cloud, the ions are subjected to the same electric field but, due to their positive charge, will move in the opposite direction, acquiring kinetic energy and striking surfaces at the entrance side of the device. These ion feedback impacts are quite often very noticeable and on most instances disturb or reduce the signal outputted by the device by so-called after-pulses or ion spots in the image of the device. In many of the prior art devices, special care is given to the design, the construction or the limitation in operating pressure range or operating voltages to avoid or reduce the effects of ion feedback. As a common solution in the art, in particular in image intensifier tube devices having component surfaces made from or contain vulnerable mono-atomic negative electron affinity layers, like for example GaAs with a Cs-based surface layer, a so-called ion barrier membrane is disposed in the vacuum chamber in order to shield off those component surfaces from the stray ions. Such membrane will prevent that stray ions will permanently damage and reduce the cathode's emissive QE. Using an ion barrier membrane however has an essential drawback. It not only blocks the feedback of stray ions, but it also considerably reduces the amount of primary electrons that can be considered to carry the signal or image information in the device towards the anode, resulting in a significantly lower emissive QE. BRIEF SUMMARY OF THE INVENTION It is an object of the invention to provide a photo cathode comprising an electron exit layer enabling a high emissive QE which is resistant to stray ion feedback and chemical attack from a Multi-Channel Plate (MCP) and anode. For this purpose a photo cathode according to the invention is proposed in wherein the photo cathode comprises a active cathode layer, having an entrance face capable for absorbing photons impinging on said cathode layer, and an exit face for releasing electrons upon impinging of said photons, an electron exit layer, in facing relationship with said exit face of said photo cathode layer for improving said releasing of said electrons, and a carbon containing layer, positioned between said exit face of said photo cathode layer and said electron exit layer, for bonding said electron exit layer to said photo cathode layer. A thin carbon containing layer is used to bond the electron exit layer to the photo cathode layer. This results in a very strong bonding of the electron exit layer to the photo cathode layer. Because the layer is thin and the carbon has advantageous material characteristics electrons are able to tunnel through the layer and are emitted to the vacuum by the electron exit layer. Because the electron exit layer has a strong bond, the cathode does not need a protecting ion barrier membrane and a longer life time and better emissive QE of the cathode is achieved. Furthermore the electron exit layer can exhibit negative electron affinity (NEA) thereby increasing the chance that electrons are emitted to the vacuum, resulting in a higher QE of the cathode. More specifically the carbon containing layer is oxidized. In a specific embodiment of the invention the carbon containing layer can be composed of a mono-crystalline diamond containing layer, a poly-crystalline diamond containing layer, a coating of nano diamond particles containing layer or of at least one atomic layer of carbon (i.e. Graphene). In yet another embodiment of the invention the photo cathode layer of the photo cathode is an III-V type photo cathode layer. In a further embodiment of the invention the electron exit layer contains at least an alkali metal. More specifically the alkali metal of the electron exit layer is cesium or rubidium. In an other embodiment of the invention the photo cathode layer of the photo cathode is an alkali metal photo cathode layer. In yet another embodiment of the invention the entrance face and exit face are located at the same side of the photo cathode layer. In an other embodiment of the invention the photo cathode further comprises an opaque carrier layer mounted to the side opposite of the side where the entrance and exit face of the photo cathode layer are located. In yet another embodiment of the invention the entrance face and the exit face are located at opposite sides of the photo cathode layer. Also embodiments of a vacuum tube with such a photo cathode to be used as an image intensifier tube or photo multiplier tube are advantageous over the prior art devices. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be explained in greater detail below with reference to the appended drawing, which shows in: FIG. 1 discloses a vacuum tube provided with a photo cathode according to the state of the art; FIG. 2 discloses an embodiment of a vacuum tube with a photo cathode according to the invention; FIG. 3 discloses another embodiment of a photo cathode according to the invention. DETAILED DESCRIPTION OF THE INVENTION For the sake of clarity in the following detailed description all like parts are denoted with the same reference numerals. FIG. 1 shows schematically, in cross section, an example of an vacuum tube, for example an image intensifier. The image intensifier is formed in a tubular housing 1 having an entrance window 2 and an exit window 3 . The tubular housing can be made of glass, as can the photo cathode layer 4 and the anode layer 5 . Inside the tubular housing 1 an ultra-high vacuum consists. On the entrance face of the entrance window photons (h.v) enter the tubular housing 1 and are absorbed by the photo cathode layer 4 . The photo cathode layer 4 creates electrons upon absorbing of the impinging photons, which electrons are released towards the vacuum inside the tubular housing 1 . The electrons that are released towards the vacuum are moving towards the entrance face 7 of a channel plate 6 . In some cases the photo cathode layer 4 is placed directly on the channel plate 6 . Such variants are known and are therefor not shown in FIG. 1 or in greater detail. Known types of channel plates 6 are micro-channel plates (MCP). At the micro-channel plate the electrons are being multiplied (secondary emission) and most of the electrons are released at the exit face 8 of the channel plate 6 into the vacuum towards the anode 5 . The anode 5 is placed on a detection/exit window 3 which can be made of glass and is also often made of an optical fibre plate, as a scintillating screen, or as a pixilated array of elements (such as a semiconductor active pixel array). One of the most important aspects of the image intensifier is the quantum efficiency (QE) which is the number of electrons that are emitted to the vacuum per incident photon. When the photons are absorbed by the photo cathode layer 4 the optical properties of the entrance window 2 and the photo cathode layer 4 and its thickness itself determine how these photons are absorbed. Thick photo cathode layers 4 have better absorption characteristics and narrow photo cathode layers 4 result in a better electron transport. Upon absorbing the photons the cathode emits electrons. Single photo cathode layers 4 have a relative low QE because not all electrons are emitted to the vacuum. Electrons can recombine with the hole inside the cathode or can be trapped at the surface because they have to little kinetic energy to be emitted to the vacuum. The material properties and crystal quality of the photo cathode and the photo cathode layer 4 determine the carrier life time and diffusion length of the carrier. A good crystal quality with little grain boundaries and small number of defects is needed to achieve long carrier lifetime and diffusion length, thereby increasing the chance an electron is being emitted to the vacuum without being recombined first. The Electron Affinity (EA) is of great importance for the emission of the electrons into the vacuum. The EA is the energy that a free electron will loose when it is emitted from the bulk to the vacuum. The value of the EA is determined by the layers comprised by the photo cathode. For most materials the EA is positive. The electrons therefore need sufficient energy to overcome the energy threshold to be emitted to the vacuum. Most photo cathode layers with a positive EA yield a low QE. Some other materials, or combinations of material layers of the photo cathode have a Negative Electron Affinity (NEA). Electrons therefore gain energy when being emitted to the vacuum when they are near that vacuum. The chance of being emitted is therefore fairly higher, resulting in a significant higher QE. The use of alkali metals such as, but not limited to, Cesium (Cs), Rubidium (Rb), Potassium (Na) or Sodium (K), mostly in the form of Cs 2 O or CsF in combination with Cesium, result in a NEA and are well known in the art. Electron exit layers are the layers where these materials are used in order to significantly increase the QE. In FIG. 1 an illustration of an electron exit layer 10 , in this case a Cs containing layer, is shown. Other types of electron exit layers are know in the art and are therefor not shown in FIG. 1 or in greater detail. These electron exit layers are used on three types of cathode layers, being metallic photo cathodes like Platinum, Gold and Silver cathodes, alkali metal based photo cathodes, usually a combination of Na, K and Antimony Sb, and III-V type photo cathodes like GaAs, AlGaAs, InGaAs, GaN and more. The metallic photo cathodes are robust but have a low QE. The alkali based photo cathodes are commonly used and the electron exit layer is commonly based on Cs. The Cs containing electron exit layer has a strong chemical bond to the cathode layer, which cathode layer has limited crystal quality, resulting in a short carrier diffusion length. Therefore thicknesses are usually limited below 200 nm resulting in limited optical absorption and therefore in a relative low QE. The III-V type photo cathodes are made from materials which are widely used in for example the semi conductor industry. The thickness of the cathode and the doping level can be well controlled. Because of the good crystal quality the value of the carrier lifetime and diffusion length are large. The QE however is very low and in order to increase the QE the use of a electron exit layer is needed. Common electron exit layers used in the III-V type photo cathodes are Cs 2 O or CsF mostly in combination with metallic Cs. The use of the electron exit layer results in a significant increase in QE. But the deposition of this electron exit layer however has to be preformed in ultra high vacuum and the bonding between the photo cathode layer and electron exit layer is purely based on van der Waals forces. Because the bonding is based on Van der Waals forces the bonding is very weak and has to be protected against chemical attack and stray ion feedback. Solutions known in the art to protect the electron exit layer are the use of an ion barrier. These ion barriers however protect the electron exit layer from chemical gasses and stray ion feedback but result in trapped electrons at that barrier therefore the QE significantly lowers. FIG. 2 shows also a vacuum tube, but this time with a bonding layer 11 between the photo cathode layer 4 and the electron exit layer 10 . This bonding layer is containing carbon which results in a very strong bonding of the electron exit layer 10 to the cathode layer 4 . Because in a particular embodiment the carbon containing layer 11 is cesiated it has a NEA resulting in a higher QE. Because the bonding is a strong chemical bonding, not just based upon van der Waals forces, the electron exit layer is much better resistant to chemical gasses and to stray ion feedback. Another important advantage is that because of the strong bond the bonding can be exposed to ambient environment without losing the NEA. The process of creating a vacuum tube is therefore simplified, not at all stages the entrance window, comprising the photo cathode layer and the strong bonded electron exit layer have to be maintained in ultra high vacuum. Furthermore in an other embodiment the bonding layer 11 can be further improved to create an even stronger bond between the electron exit layer 10 and the photo cathode layer 4 by oxidizing the bonding layer 11 , which is shown in FIG. 2 . Examples of, but not limited to, carbon containing layers to be used as a bonding layer 11 for the electron exit layer 10 on the photo cathode layer 4 are the use of mono-crystalline diamond containing layers, poly-crystalline diamond containing layers, coating of nano diamond particles layers, diamond like carbon (DLC) containing layers, and graphene containing layers. FIG. 3 discloses another embodiment of a photo cathode according to the invention. In this embodiment the photo cathode comprises an entrance and an exit face, which are positioned or located at the same side of the photo cathode layer. Electrons are emitted from the same side (the exit face) as the side (the entrance face) on which the photons impinge. On the opposite side an opaque carrier 12 is mounted to the photo cathode layer, serving as a reflective barrier for the electrons being released in the cathode layer material.
A photo cathode for use in a vacuum tube including a cathode layer, having an entrance face capable of absorbing photons impinging on the cathode layer, and an exit face for releasing electrons upon impinging of the photons, and an electron exit layer, in facing relationship with the exit face of the cathode layer for improving the releasing of the electrons, and a carbon containing layer, positioned between the exit face of the cathode layer and the electron exit layer, for bonding the electron exit layer to the cathode layer.
7
FIELD OF THE INVENTION The present invention relates to a method of growing diamonds by reduction of C 70 Buckminster fullerenes in the presence of diamond seed particles. BACKGROUND OF THE INVENTION Diamond, being the hardest substance known, is of great commercial and scientific value. It is inert to chemical corrosion and can withstand compressive forces and radiation. It is an electrical insulator having extremely high electrical resistance but is an excellent thermal conductor, conducting heat better than most other electrical insulators. Diamond is structurally similar to silicon but is a wide-band-gap semiconductor (5 eV) and so is transparent to UV-visible light and to much of the infrared spectrum. It has an unusually high breakdown voltage and low dielectric constant. These properties, coupled with recent advances, have led to speculation that diamond might find widespread application in high speed electronic devices and devices designed to be operated at high temperature. If it can be doped successfully diamond could become an important semiconductor material on which new or replacement device applications may be based. While silicon chips can withstand temperatures up to 300° C., it is estimated that diamond devices may be able to withstand considerably higher temperatures. Diamond film already find applications as hard protective coatings. Because of these useful properties, synthetic diamond has great potential in research and commercial applications. Synthetic diamonds are now produced by two known methods: a high pressure process in which carbonaceous material is compressed into diamond using high pressure anvils; and the more recent technique of chemical vapour deposition (CVD) in which diamond films are deposited on an appropriate substrate by decomposing a carbon containing gaseous precursor. Of recent particular scientific interest are a class of carbon structures known as Buckminster fullerenes which are formed by an integral number of carbon atoms which combine to form a closed, roughly spherical structure. Two prominent fullerenes are C 60 and C 70 , which are spherical structures comprising 60 and 70 carbon atoms, respectively. The successful transformation of C 60 and C 70 into diamond at high pressure has been disclosed by Manuel Nunez Regueiro, Pierre Monceau, Jean-Louis Hodeau, Nature, 355, 237-239 (1992) and Manuel Nunez Regueiro, L. Abello, G. Lucazeau, J. L. Hodeau, Phys. Rev. B, 46, 9903-9905 (1992). The transition of C 60 to diamond has also been studied by Hisako Hirai, Ken-ichi Kondo and Takeshi Ohwada, Carbon, 31, 1095-1098 (1993). It is also known that C 70 can accelerate the nucleation of diamond thin film formation on metal surfaces using CVD as disclosed by R. J. Meilunas, R. P. H. Chang, S. Liu, M. M. Kappes, Appl. Phys. Lett., 59, 3461-3463 (1991), and R. J. Meilunas, R. P. H. Chang, S. Liu, M. M. Kappes, Nature, 354, 271 (1991). A high growth rate of diamond film using fullerene precursors in an argon microwave plasma with or without hydrogen has been reported by D. M. Gruen, S. Liu, A. R. Krauss and X. Pan, J. Appl. Phys., 75, 1758-1763 (1994), and D. M. Gruen, S. Liu, A. R. Krauss, J. Luo and X. Pan, Appl. Phys. Lett., 64, 1502-1504 (1994). Recently, dispersed diamond particles with diameters in the range of 20-150Åhave been observed in fullerene-rich soot as disclosed by Vladimir Kuznetsov, A. L. Chuvilin, E. M. Moroz, V. N. Kolomiichuk, Sh. K. Shaikhutdinov, Yu. V. Butenko, Carbon, 32, 873-882 (1994), and Vladimir L. Kuznetsov, Andrey L. Chuvilin, Yuri V. Butenko, Igor Yu. Malkov, Vladimir M. Titov, Chem. Phys. Lett., 222, 343-348 (1994). It would be very advantageous and of potentially significant commercial value to be able to grow diamond particles with much larger particle sizes. SUMMARY OF THE INVENTION It is an object of the present invention to provide an economical process for growing diamonds which does not require high temperatures or pressures. The present invention provides a process for the formation of diamond particles of mean diameters in excess of 10 μm, grown from diamond powder nucleation seeds of approximately 1.5 μm mean diameter. C 70 is reduced in the presence of reducing or reacting agents such as selenium or phosphorous at moderate temperatures and pressure. In one aspect of the invention there is provided a process for growing diamonds. The method comprises reducing a quantity of C 70 in the presence of diamond seed particles to cause at least some of the diamond seed particles to grow. In another aspect of the invention, a process for growing diamonds is provided which comprises providing diamond seed particles, and providing a quantity of C 70 powder and a reducing or reacting agent both in flow communication with the diamond powder. The process includes heating the C 70 , the reducing agent and the diamond powder under vacuum at an effective temperature and for an effective period of time to cause some of the C 70 to be reduced by the reducing agent and deposit onto at least some of the diamond seed particles causing the particles to grow larger. In this aspect of the invention the preferred reducing agent is selenium or phosphorous, the effective temperature is about 550° C. and the effective period of time is from about 18 days to about 60 days. In another aspect of the invention there is provided a process for growing diamonds. The process comprises providing a plurality of diamond seed particles having a mean diameter and providing a quantity of C 70 powder and a reducing agent. The C 70 powder and the reducing agent are in flow communication with the diamond seed particles. The process includes the step of heating the C 70 powder to produce C 70 in the vapour phase, and heating the reducing agent and the diamond seed particles under vacuum at a temperature of from about 500° C. to about 600° C. and for a period of time of from about 18 days to about 60 days to cause a portion of the C 70 in the vapour phase to be reduced by the reducing agent and deposit onto and increase the mean diameter of at least one of the diamond seed particles. BRIEF DESCRIPTION OF THE DRAWINGS The method of diamond growth from C 70 forming the subject invention will now be described, reference being had to the accompanying drawings, in which: FIG. 1 illustrates an apparatus used for growing diamonds from diamond seeds according to the present invention; FIG. 2 is an SEM micrograph of C 70 polycrystalline powder used in the method according to the present invention; FIG. 3 is an SEM micrograph of a sample of the diamond seeds (average size ˜1.5 μm) used in the method of the present invention; FIG. 4 is a scanning electron micrograph (SEM) of two diamond particles found in the lower portion of the capillary shown in FIG. 1 after the assembly was heated at 550° C. for 20 days in the presence of selenium; FIG. 5 displays a typical laser micro-Raman spectrum of the C 70 polycrystalline powder of FIG. 2; FIG. 6 displays a laser micro-Raman spectrum of one of the particles shown in FIG. 4; FIG. 7 shows the structure of C 70 ; and FIG. 8 shows the structure of C 60 . DETAILED DESCRIPTION OF THE INVENTION Referring to FIG. 1, approximately 18 to 20 mg of C 70 (98%), approximately 11 mg of elemental selenium powder (99.5%, -325 Mesh particle size, Alfa) or red phosphorous powder (99%, -100 Mesh particle size, Alfa) and trace quantities of diamond seed powder (average diameter of 1.5 μm) were placed generally at 10 in a 1 cm diameter×10 cm long pyrex tube 12. A trace quantity (<1 mg) of diamond powder shown generally at 14 was loaded into a small pyrex capillary (1.0 mm×50 mm) 16, which was then set into the larger pyrex tube 12 as shown in FIG. 1. The entire tube assembly was evacuated and sealed under vacuum (˜2×10 -5 torr). After heating the tube assembly at a temperature of about 550° C. in a tube oven (not shown) with controllable temperature for 20 to 30 days, various portions of the product were examined using laser micro-Raman Spectroscopy and scanning electron microscopy (SEM). Crystallite sizes and shapes of the diamond seeds and the reaction produces were examined using scanning electron microscopy (HITACHI model S-570, Japan). The identification of the crystallites as diamond was accomplished using Laser micro-Raman spectroscopy. An important advantage of micro-Raman spectroscopy is that the sample crystallite can be located by a charge coupled device (CCD) camera at high magnification. This enabled both the size of the crystallite and its identity to be determined simultaneously. A Kr ion laser tuned to 530.87 nm was used as the excitation source. An approximately 2 mW beam was focused down to a 3 micrometer diameter spot. Raman spectra were detected in a back scattering geometry using a triplemate spectrometer (SPEX Industries Inc. model 1877D) equipped with a microscope (Micromate model 1482D) and a liquid nitrogen cooled CCD detector (Princeton Instruments Inc. Model LN/CCD). An SEM image of the C 70 powder that was used in the above-described experiment is shown in FIG. 2. The plate-like crystallites are shown for the purpose of comparison with diamond crystallites. FIG. 3 shows an SEM image of a sample of the diamond powder that was used as seed diamond. Examination of several such samples showed that particle diameters rarely exceeded 2 μm and no particle with a diameter in excess of 3 μm was seen. In contrast, FIG. 4 shows two crystallites with average diameters, respectively, of approximately 8 μm and 17 μm that were found among the reaction products of the fullerene seeded with small diamond particles and with selenium used as the reducing or reacting agent after 20 days of heating at 550° C. Only approximately 1% of the diamond seeds were found to be enlarged to this extent. However, on a volume basis the overall enlargement of the seeds was substantial. The micro-Raman spectrum of one of these crystallites is shown in FIG. 6. The characteristic single peak at approximately 1328 cm -1 is unequivocal proof that the particle is diamond. For comparison, the Raman spectrum of C 70 that was used in this work is shown in FIG. 5. There is no such peak at 1328 cm -1 . The 26 relatively strong vibrational mode frequencies obtained from the spectrum of FIG. 5 are in good agreement with values previously disclosed in R. A. Jishi, M. S. Dresselhaus, G. Dresselhaus, Kai-An Wang, Ping Zhou, A. M. Rao and P. C. Eklund, Chem. Phys. Lett., 206, 187 (1993). These vibrational mode frequencies are also in good agreement with group theoretical analysis, see M. S. Dresselhaus, G. Dresselhaus and R. Saito, Phys. Rev. B, 45, 6234 (1992). In all C 70 has 53 Raman active modes. Most of the larger diamond particles that were produced were found in the capillary 16 (FIG. 1) in which the seed diamonds were deposited. This strongly suggests that gas-phase C 70 was responsible for the growth of the seed diamonds. C 70 has a substantial vapour pressure at 550° C. The Raman spectrum of the material that remained at the bottom of the larger tube 10 after 20 days corresponded to that of unreacted C 70 . Analogous experiments were also conducted using C 60 instead of C 70 . These experiments using C 60 did not produce any measurable growth in the size of the diamond seed particles based on comparison of SEMs taken before and after prolonged exposure of the seeds to C 60 under essentially the same conditions of temperature, pressure and time as with the C 70 . In addition to selenium and phosphorous, other elemental reducing agents such as sodium, potassium and sulphur are contemplated by the inventors to be effective in reducing C 70 and at temperatures higher than in the range 500° to 600° C. The following is a possible growth mechanism proposed by the inventors. The mechanism is speculative, so it will be understood that the following is meant to be a non-limiting explanation. The structure of C 70 is shown generally at 40 in FIG. 7 and can be compared to the structure of C 60 shown at 70 in FIG. 8. The carbon atoms 42 comprising C 70 are hybridized intermediately between sp 2 (as in graphite) and sp 3 , the hybridization of carbon in diamond. When one of the bonds is broken in a fullerene, the two carbons comprising the broken bond have a choice between sp 2 and sp 3 hybridization according to the nature of the reaction partner that reacts at the broken bond. Referring to FIG. 8, C 60 has two types of C--C bonds; a so-called "single bond" 44 at the edges between pentagonal and hexagonal faces, and "double bond" 46 at the edges between hexagonal faces. However, all carbon atoms are vertices of both hexagonal and pentagonal faces. Referring to FIG. 7, C 70 has, additionally, C--C bonds 50 that are edges separating two hexagonal faces and, also, vertices of hexagonal faces only. The inventors speculate that it is these additional carbon-carbon bonds 50 in C 70 that break to initiate diamond growth. It is speculated that the diamond seed acts as a template whose surface dangling bonds ensure that the carbon atoms of the newly ruptured C--C bond of the C 70 molecule adopt the sp 3 hybridization required to continue the diamond growth. Ultimately all of the carbon atoms of the C 70 molecule could be incorporated into the diamond. Although the process in accordance with the present invention occurs at relatively low temperatures and pressures, it makes use of the free energy stored in the C 70 molecule during its formation at the very high temperatures of the carbon arc used to generate it. This increase in free energy (over that of the graphite precursor in the form of the electrodes of the arc) manifests itself in the intermediate hybridization characteristic of the fullerenes. Recent theory predicts the involvement of a non-planar intermediate which has one sp 3 and one sp hybridized carbon, see Robert L. Murray, Douglas L. Strout, Gregory K. Odom and Gustavo E. Scuseria, Nature, 366, 665-667 (1993). In order to channel this free energy into diamond formation some of the C--C bonds in C 70 must be induce to rupture. This is achieved by the presence of materials such as selenium or phosphorous that donate electrons to the C 70 and, therefore, facilitate bond breaking. The present invention advantageously provides an economical method of growing diamonds from seed diamond particles with C 70 which does not require high pressures or temperatures as in the known methods. The result that C 70 , but not C 60 , can be readily reduced in the presence of a reducing agent was completely unexpected. While the process has been described with respect to the preferred process, those skilled in the art will appreciate that numerous variations of this process may be made to grow diamonds which still fall within the ambit of the following claims.
A method of growing diamond crystals in excess of 10 μm in diameter from industrial diamond "seeds" having mean diameters of approximately 1.5 μm is disclosed. The diamonds are grown by exposing the seed diamonds to C 70 in the presence of reducing agents such as phosphorus or selenium in evacuated cells at moderate temperatures and pressures.
2
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to an airbag module for protecting a driver and a passenger upon a vehicle collision. [0003] 2. Discussion of the Related Art [0004] Recently, consumers think that the safety of a vehicle, as well as the performance or design of a vehicle, is a very important consideration in choosing a vehicle. Therefore, car manufacturers have established the development of technologies for securing the safety of a vehicle as a primary goal and are devoting themselves to this goal. Under the circumstance of the development of technologies, airbag modules are receiving attention as means for improving the safety of a passenger, and the technologic development for these means are in rapid progress. Also, in recent years, airbag modules are being regarded as an essential item of a vehicle. [0005] However, an airbag module must have sufficient safety because it carries out the function of protecting a passenger by deploying an airbag cushion. For this, strength of more than a predetermined level should be maintained, and thus parts of the airbag module are made of metal material having a large weight. However, this makes the weight of the airbag module larger, thereby decreasing the energy efficiency of the vehicle. [0006] Further, the airbag module is constructed by joining various parts, but the joining process is not easy. Hence, although measures for improving working efficiency have been sought, any proper solution for this has not been secured yet. SUMMARY OF THE INVENTION [0007] The present invention has been made in an effort to provide an airbag module which can improve working efficiency, and is made of a lightweight material while maintain sufficient strength. [0008] To achieve the foregoing object, there is provided an airbag module according to the present invention, comprising: a cushion assembly including an airbag cushion; an inflator for supplying gas to the airbag cushion to deploy the airbag cushion; a housing for containing the cushion assembly, and having a through hole for arranging the inflator therethrough; and a cushion support for supporting the cushion assembly, and including through rings for passing the inflator therethrough so as to be supported by the inflator arranged through the through hole. [0009] Preferably, the through rings are formed in the same shape as a cross sectional shape of the inflator so that the inflator may be compressed and fitted to the through rings. Preferably, through ring ribs are formed on the surface of the through rings such that the yield stress thereof may be increased. Preferably, through ring rib grooves are formed on the inner surface of the through hole of the housing to keep the gas ejected from the inflator from being leaked out by the compression of the through ring ribs. [0010] A gas inlet and outlet may be formed on the cushion support such that the gas supplied from the inflator can be introduced into the airbag cushion. [0011] The cushion assembly may include a cushion cushion rings to be suspended on the cushion support so as to be supported by the cushion support. [0012] The airbag module may comprise side caps which are fitted to both opposite ends of the inflator arranged through the through hole such that the inflator may be fixed to the housing. Preferably, the side caps are forcedly fitted to the housing. Fixing grooves are formed at the ends of the through hole to which the side caps are fitted, and fixing projections are formed on the surfaces of the side caps such that the side caps may be fitted and fixed to the through hole. [0013] Side cap ribs may be formed on the surfaces of the side caps in order to increase the yield stress of the side caps. Also, side cap rib grooves may be formed in order to prevent the gas supplied from the inflator from being leaked out by the compression of the side cap ribs. [0014] Slots may be formed on the outer surface of the inflator which is to be covered by the side caps, and slot projections may be formed on the side caps so that the side caps may be fitted to the slots. [0015] The present invention has the following effects. [0016] First, the present invention can improve working efficiency because the connection of the airbag module is made easier. [0017] Second, the present invention can increase safety by maintaining sufficient rigidity while reducing the number of parts. [0018] Third, the present invention can reduce self-weight because a strength of a required level can be secured even if the airbag module is made of a lightweight material, such as plastic. [0019] Fourth, the present invention can cut down costs since sufficient rigidity can be maintained even with cheap materials. [0020] Fifth, the present invention allows the airbag cushion to be deployed at the right time by suppressing the leakage of the gas generated from the inflator as much as possible. BRIEF DESCRIPTION OF THE DRAWINGS [0021] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings: [0022] FIG. 1 is an exploded perspective view showing an airbag module according to a first embodiment of the present invention; [0023] FIG. 2 is an exploded perspective view showing an airbag module according to a second embodiment of the present invention; [0024] FIG. 3 is an exploded perspective view showing an airbag module according to a third embodiment of the present invention; and [0025] FIG. 4 is an exploded perspective view showing an airbag module according to a fourth embodiment of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0026] Hereinafter, a first embodiment of the present invention will be described with reference to FIG. 1 . [0027] An airbag module 100 of this embodiment includes a cushion assembly 110 for accommodating an airbag cushion (not shown) in a folded state, the airbag cushion being deployed at a high speed by an incoming gas upon collision, an inflator 142 for deploying the airbag cushion by supplying, to the airbag cushion (not shown), a high-pressure gas generated by the explosive force of a chemical reaction in a vehicle collision; a housing 130 for containing the cushion assembly 110 , and having a through hole 132 for arranging the inflator 142 therethrough; and a cushion support 120 for supporting the cushion assembly 110 , and including through rings 124 for passing the inflator 140 therethrough so as to be supported by the inflator arranged through the through hole 132 . [0028] The cushion assembly 110 preferably includes cushion rings 112 to be suspended on the cushion support 120 such that it is sufficiently supported by the cushion support 120 to secure its position. [0029] Also, the cushion support 120 preferably includes a gas inlet and outlet 122 formed thereon such that gas supplied from a gas ejection opening 142 of the inflator 140 arranged through the through rings 124 can be supplied to the airbag cushion provided at the cushion assembly 110 . [0030] The way the components are joined together in this embodiment will be described. [0031] The cushion rings 112 are suspended and fixed to the cushion support 120 so that the cushion assembly 110 may be supported by the cushion support 120 to secure its position. Then, the cushion support 120 joined to the cushion assembly 110 is contained in the housing 130 , and thereafter the inflator 140 is inserted into the through hole 132 so as to pass through both the through hole 132 and the through rings 124 , thus fixing the cushion support 120 to the housing 130 . Resultantly, the cushion assembly 110 is firmly arranged in the housing 130 . [0032] Hereinafter, the advantages of the airbag module in this embodiment will be described. [0033] As discussed above, the airbag module 100 of this embodiment is not fastened by connection means, such as bolts and nuts, so no additional fastening means are required. [0034] Further, if the airbag module is manufactured by connecting means such as bolts and nuts, a local stress concentration is generated in the connected regions. Due to this, it is difficult to manufacture an airbag module by using a material, such as plastic, having a relatively weak rigidity compared with metals but having a small weight. In this embodiment, however, the connection of the airbag module is done by the inflator, which is a component of the airbag module, so there is no room for a local stress concentration. Resultantly, a material, such as plastic, having a weak rigidity but being lightweight can be used. [0035] Hereinafter, an airbag module 200 according to a second embodiment of the present invention will be described with reference to FIG. 2 . [0036] The construction and operation of the airbag module 200 according to this embodiment are substantially identical to those of the airbag module 100 according to the first embodiment, except that through ring ribs 226 are formed on through rings 224 , and through ring rib grooves 234 are formed on the inner surface of a through hole 232 . Therefore, a repeated description of the airbag module 100 according to the first embodiment of the present invention will be omitted. [0037] Through ring ribs 226 for increasing yield stress are formed on the through rings 224 provided on the cushion support 220 to keep the through rings 224 from being damaged by a stress exerted to the through rings 224 when the inflator 140 is attached through the through rings 224 . Further, through ring rib grooves 234 are formed on the inner surface of the through hole 232 of a housing 230 to keep the gas ejected from the inflator 140 from being leaked out by the compression of the through ring ribs 226 . [0038] As discussed above, gas is supplied from a gas ejection opening 142 of the inflator 140 . Although there is a possibility that the gas might be leaked out between the cushion support and the housing, the through ring ribs 226 and the through ring rib grooves 234 are attached to each other to prevent the leakage of the gas. Therefore, a large amount of gas is supplied to the airbag cushion, and resultantly the deployment speed of the airbag cushion becomes higher, thereby making it possible to deploy the airbag cushion at the right time. [0039] Hereinafter, an airbag module 300 according to a third embodiment of the present invention will be described with reference to FIG. 3 . [0040] The construction and operation of the airbag module 300 according to this embodiment are substantially identical to those of the airbag module 200 according to the second embodiment, except that the airbag module 300 further includes a side cap 350 . Therefore, a repeated description of the airbag module 200 according to the second embodiment of the present invention will be omitted. [0041] The airbag module 300 includes side caps 350 which are fitted to both opposite ends of the inflator 140 arranged through the through hole 232 such that the inflator 140 may be sufficiently fixed to the housing 230 . [0042] By including the side caps 350 , the inflator 140 is pushed back in a direction that the inflator 140 passes through the through hole 232 , thereby preventing the airbag module from being disconnected. Also, if the side caps 350 are arranged to be forcedly fitted into the housing 230 , this prevents the gas ejected from the inflator from being leaked out through the through hole 232 , thereby ensuring the deployment of the airbag cushion at the right time. [0043] Hereinafter, an airbag module 400 according to a fourth embodiment of the present invention will be described with reference to FIG. 4 . [0044] The construction and operation of the airbag module 400 according to this embodiment are substantially identical to those of the airbag module 300 according to the third embodiment, except for the construction of side caps 450 and the shape of the inner surface of a through hole. Therefore, a repeated description of the airbag module 300 according to the third embodiment of the present invention will be omitted. [0045] In the airbag module 400 according to this embodiment, fixing grooves 436 are formed at the ends of the through hole 432 to which the side caps 450 are fitted, and fixing projections 452 are formed on the surfaces of the side caps 450 such that the side caps 450 may be fitted and fixed to the through hole 432 . [0046] Optionally, side cap ribs 454 may be formed on the surfaces of the side caps 450 in order to increase the yield stress of the side caps 450 and strengthen the rigidity of the side caps 450 . Also, side cap rib grooves 432 capable of compressing the side cap ribs 454 may be formed in order to prevent the gas supplied from the inflator 440 from being leaked out along the through hole 432 . [0047] Optionally, slots 444 may be formed on the outer surface of an inflator 440 so as to prevent the inflator 440 from rocking or prevent the attachment thereof from becoming incomplete, and slot projections 451 may be formed on the side caps 450 so that the side caps 450 may be fitted to the slots 444 . [0048] As described above, the present invention has been described with reference to the embodiment shown in the drawings, but it is just for illustration only and those skilled in the art will understand that there are various modifications and equivalent other embodiments therefrom. Accordingly, the sincere technical scope of the invention should be defined based on the technical spirit of the appended claims. [0049] The present invention can be used in the technology of development of an airbag module that secures the safety of a passenger in a vehicle collision.
Disclosed is an airbag module which can improve working efficiency because it is easy to assemble, reduce weight while maintaining sufficient rigidity, and ensure sufficient safety. The airbag module comprises: a cushion assembly including an airbag cushion; an inflator for supplying gas to the airbag cushion to deploy the airbag cushion; a housing for containing the cushion assembly, and having a through hole for arranging the inflator therethrough; and a cushion support for supporting the cushion assembly, and including through rings for passing the inflator therethrough so as to be supported by the inflator arranged through the through hole.
1
This application is a continuation of U.S. application Ser. No. 07/452,457 filed on Dec. 18, 1989 now abandoned. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to new drilling fluids based on ester oils and to invert drilling muds based thereon which combine high ecological compatibility with good stability and performance properties. 2. State of Related Art It is known that liquid drilling fluids for sinking bores in rock and bringing up the rock cuttings are slightly thickened, water-based or oil-based fluid systems. Oil-based systems are being increasingly used in practice, particularly in offshore drilling or in the penetration of water-sensitive layers. Oil-based drilling fluids are generally used in the form of so-called invert emulsion muds which consist of a three-phase system, namely: oil, water and finely divided additives, including in particular emulsifiers and emulsifier systems, weighting agents, fluid loss additives, alkali reserves, viscosity regulators and the like, for stabilizing the system as a whole and for establishing the desired performance properties. Full particulars can be found, for example, in the Article by P. A. Boyd et al entitled "New Base Oil Used in Low-Toxicity Oil Muds" in the Journal of Petroleum Technology, 1985, 137 to 142 and in the Article by R. B. Bennet entitled "New Drilling Fluid Technology--Mineral Oil Mud" in Journal of Petroleum Technology, 1984, 975 to 981 and the literature cited therein. Oil-based drilling fluids were originally made from diesel oil fractions containing aromatic constituents. For the purposes of detoxification and reducing the ecological problems thus created, it was then proposed to use hydrocarbon fractions substantially free from aromatic compounds--now also known as "nonpolluting oils"--as the continuous oil phase, cf. the literature cited above. Although certain advances were achieved in this way through elimination of the aromatic compounds, a further reduction in the environmental problems caused by drilling fluids of the above type seems to be urgently required. This applies in particular to the sinking of offshore wells for the development of oil and gas sources because the marine ecosystem is particularly sensitive to the introduction of toxic and non-readily degradable substances. The relevant technology has for some time recognized the significance of ester-based oil pleases for solving these problems. Thus, U.S. Pat. Nos. 4,374,737 and 4,481,121 describe oil-based drilling fluids in which nonpolluting oils are said to be used. Non-aromatic mineral oil fractions and vegetable oils of the peanut oil, soybean oil, linseed oil, corn oil and rice oil type, and even oils of animal origin, such as whale oil, are mentioned alongside one another as nonpolluting oils of equivalent rank. The ester oils of vegetable and animal origin mentioned here are all triglycerides of natural fatty acids which are known to be environmentally safe and which, ecologically, are distinctly superior to hydrocarbon fractions, even where they have been de-aromaticized. Interestingly, however, not one of the Examples in the US patents cited above mentions the use of such natural ester oils in invert emulsion drilling muds. Mineral oil fractions are used throughout as the continuous oil phase. In its general descriptive part, U.S. Pat. No. 4,491,121 mentions not only triglycerides, but also a commercial product "Arizona 208" of the Arizona Chemical Company, Wayne, N.J., which is a purified isooctyl-monoalcohol ester of high-purity tall oil fatty acids. An ester of a monofunctional alcohol and monofunctional carboxylic acids, mentioned for the first time here, is described as equivalent to triglycerides of natural origin and/or de-aromaticized hydrocarbon fractions. The cited US patent does not contain any reproducible Examples relating to the use of such an ester of monofunctional components. DESCRIPTION OF THE INVENTION Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities of ingredients or reaction conditions used herein are to be understood as modified in all instances by the term "about". The investigations on which the present invention is based have shown that the use of readily degradable oils of vegetable and/or animal origin, which was considered in the prior art, is not feasible for practical reasons. The rheologic properties of such oil phases cannot be controlled for the wide temperature range required in practice of 0° to 5° C. on the one hand up to 250° C. and higher on the other hand. The teaching of the present invention is based on the observation that it is in fact possible to produce oil-based invert drilling fluids based on ester oils of high environmental compatibility which correspond in their storage and in-use behavior to the best of the hitherto known oil-based drilling fluids, but have the additional advantage of increased environmental compatibility. Two key observations in this regard dominate the teaching according to the invention: The triglycerides accumulating in the form of natural oils are not suitable for the production of mineral-oil-free oil-based invert drilling fluids, whereas the esters of monofunctional carboxylic acids with monofunctional alcohols derived from those oils or fats are suitable for the production of such drilling fluids. The second key observation is that ester oils of the present type do not in fact show the same in-use behavior as the mineral oil fractions used hitherto based purely on hydrocarbons. In practical application, the ester oils of monofunctional components of the invention undergo partial hydrolysis, resulting in the formation of free fatty acids. These free fatty acids react in turn with the alkaline constituents always present in invert drilling fluids, for example with the alkali reserve used to prevent corrosion, to form the corresponding salts. However, salts of highly hydrophilic bases and the acids in the range of from about C 16 to C 24 commonly encountered in fats and oils of natural origin are known to be compounds having comparatively high HLB values which lead in particular to the formation and stabilization of o/w emulsions. Use is made of this to a very considerable extent in the field of detergents and cleaning preparations. However, the formation of undesirably large quantities of such o/w emulsifier systems must interfere with the w/o emulsions required for solving the problem addressed by the invention and, hence, leads to problems. The teaching of the present invention as described in the following shows how invert drilling fluids based on ester oils can be effectively used in practice despite these difficulties inherent in the system. In a first embodiment, therefore, the present invention relates to the use of selected esters--flowable and pumpable at temperatures in the range of from 0° to 5° C.--of monofunctional C 2-12 alcohols (alkanols) and olefinically mono- and/or polyunsaturated C16-24 monocarboxylic acids or mixtures thereof with small quantities of other, more especially saturated monocarboxylic acids as the oil phase, or at least a substantial part of the oil phase, of invert drilling muds which contain in a continuous oil phase a disperse aqueous phase and also emulsifiers, weighting agents, fluid loss additives and, if desired, other standard additives together with an alkali (alkaline) reserve, with the proviso that strong hydrophilic bases, such as alkali metal hydroxides and/or diethanolamine, are not used in significant quantities. Lime (calcium hydroxide) is often added as the alkali reserve, more especially for protection against inrushes of CO 2 and/or H 2 S into the drilling fluid and hence for protection against corrosion. An addition of lime such as this may be used as the alkali reserve in accordance with the invention. However, it is important to ensure that only comparatively small quantities of this alkaline component are incorporated. In a preferred embodiment of the invention, the maximum addition of lime is of the order of 2 lb/bbl (lime/oil mud) and is thus distinctly below the quantities typically used in practice in oil-based invert drilling fluids. In another embodiment, the invention relates to mineral-oil-free invert drilling fluids which are suitable for the offshore development of oil and gas sources and, in a continuous oil phase based on ester oils, contain a disperse aqueous phase together with emulsifiers, weighting agents, fluid loss additives and, if desired, other standard additives. The new drilling fluids are characterized in that the oil phase consists at least substantially of esters of monofunctional C 2-12 alcohols and olefinically mono and/or polyunsaturated C 16-24 monocarboxylic acids and in that the w/o emulsion is mildly alkalized and, where lime is added, this alkali reserve preferably does not exceed quantities of about 2 lb/bbl (lime/oil mud). The lime content is preferably slightly below this limit. The ester oils selected in accordance with the invention which are intended to form the entire continuous oil phase of the invert drilling muds or at least a substantial part thereof (i.e. over 50% by weight thereof) are discussed first in the following. As already stated, an important criterion lies in the choice of esters which may be assigned to the class of reaction products of monofunctional carboxylic acids with monofunctional alcohols. In addition, however, it is intended in accordance with the invention exclusively or at least predominantly to use C 16 -C 24 carboxylic acids within this class. The carboxylic acids may be derived from unbranched or branched hydrocarbon chains, preferably linear chains. Monocarboxylic acids of this type and of the C 16 to C 24 range and esters thereof are unsuitable as predominantly saturated hydrocarbon compounds due to their comparatively high solidification points. Even then, however, esters of this type are flowable and pumpable down to temperatures of 0° to 5° C. providing an adequate level of olefinically unsaturated ester constituents is guaranteed. In the preferred embodiment of the invention, therefore, esters of the described type of which more than 70% by weight and preferably more than 80% by weight are derived from olefinically unsaturated C 16-24 carboxylic acids are used. Important natural starting materials are carboxylic acid mixtures which contain at least 90% by weight olefinically unsaturated carboxylic acids in the above C range. The unsaturated carboxylic acids may be mono- and/or polyolefinically unsaturated. Where carboxylic acids or carboxylic acid mixtures of natural origin are used, the double ethylenic double bond in particular and, to a lesser extent, even a triple ethylenic double bond per carboxylic acid molecule plays a role in addition to a single ethylenic double bond in the molecule. Particulars of this are given in the following. In conjunction with the choice of esters of monofunctional reactants in accordance with the invention, the choice of such a comparatively highly unsaturated carboxylic acid component in the ester oils ensures that the ester oils and, ultimately, the final invert emulsions show the rheologic properties required in practice, particularly at relatively low temperatures. The comparatively highly unsaturated ester oils containing 16 to 24 C atoms in the monocarboxylic acid component, which are used in accordance with the invention, have solidification points (pour point and setting point) below -10° C. and more especially below -15° C. in the preferred embodiment. Despite this high mobility at low temperatures, the molecular size of the ester oil prescribed in accordance with the invention ensures that the flashpoints of the ester oils are sufficiently high, being at least 80° C., and generally exceeding a temperature limit of approximately 100° C. Ester oils having flashpoints above 160° C. are preferred. Ester oils of the described type showing high mobility, even at low temperatures, and having flashpoints of 185° C. or higher can be produced without difficulty. In conjunction with these high flashpoints determined by the size of the molecule, it is possible at the same time to ensure that the viscosity values are within the required limits. Thus, preferred ester oils of the described type show a Brookfield (RVT) viscosity at a temperature of 0° to 5° C. of not more than 55 mPa.s and preferably of at most 45 mPa.s or lower. It is possible to adjust values of 30 or even higher, for example in the range of from 20 to 25 mPa.s, at temperatures in the range indicated. Among the unsaturated ester oils suitable for use in accordance with the invention, there are two sub-classes of particular importance. The first of these sub-classes is based on unsaturated C 16-24 monocarboxylic acids of which no more than about 35% by weight are diolefinically and, optionally, polyolefinically unsaturated. In their case, therefore, the content of di-and polyunsaturated carboxylic acid residues in the ester oil is comparatively limited. Within this sub-class it is preferred that at least about 60% by weight of the carboxylic acid residues are monoolefinically unsaturated. In contrast to the first sub-class described above, the second sub-class of ester oils of particular significance is derived from C 16-24 unsaturated monocarboxylic acid mixtures of which more than 45% by weight and preferably more than 55% by weight are derived from diolefinically and/or polyolefinically unsaturated acids within the above C range. The most important monoethylenically unsaturated carboxylic acids within the above carbon range are hexadecenoic acids (palmitoleic acid (C 16 )), oleic acid (C 18 ), the related ricinoleic acid (C 18 ) and erucic acid (C 22 ). The most important di-unsaturated carboxylic acid within the range in question here is linoleic acid (C 18 ) while the most important triethylenically unsaturated carboxylic acid is linolenic acid (C 18 ). Selected individual esters formed from an unsaturated monocarboxylic acid and a monoalcohol can be used as the ester oil in accordance with the invention. One example of such esters are the esters of oleic acid, for example of the oleic acid isobutyl ester type. So far as the rheology of the system is concerned and/or for reasons of availability, it is frequently desirable to use esters from acid mixtures. This is of importance so far as meeting the above-stated specifications of the two-classes for preferred ester oils is concerned. As already mentioned, the first of these two sub-classes is distinguished by the fact that its content of di-unsaturated and polyunsaturated acids is limited and does not exceed about 35% by weight. Vegetable oils of natural origin, of which the hydrolysis or transesterification gives mixtures of carboxylic acids or carboxylic acid esters of the type required here, are for example palm oil, peanut oil, castor oil and, in particular, rapeseed oil. Suitable rapeseed oils are both traditional types of high erucic acid content and also the more modern types of reduced erucic acid content and increased oleic acid content. Ester oils of the first sub-class which correspond to this definition are particularly important for the simple reason that problems possibly arising from the lack of stability to oxidation are reduced. In practice, the drilling fluid is of course continuously pump-circulated and, in the process, is brought constantly into contact with atmospheric oxygen, often over a large area and at least slightly elevated temperatures, for the purpose of separating out the rock cuttings brought up, for example by sieving. However, carboxylic acid mixtures of the second subclass mentioned above are also of considerable practical significance for use in accordance with the invention. This is attributable in part to their broad accessibility from natural fats of animal and/or vegetable origin. Classic examples of oils which have a high content of C 16-18 or C 16-22 carboxylic acids and which, at the same time, contain at least about 45% of at least diethylenically unsaturated carboxylic acids are cottonseed oil, soybean oil, sunflower oil and linseed oil. The tall oil acids isolated during the recovery of cellulose also fall within this range. However, starting materials of the last type are generally distinguished by more or less large additional contents of resin constituents. A typical animal starting material for the production of corresponding carboxylic acid mixtures is fish oil, particularly herring oil. As already mentioned, the ester oils used in accordance with the invention can be certain selected individual esters corresponding to the above definition. However, mixtures of esters of corresponding monocarboxylic acids and monoalcohols will normally be present. In this regard, the scope of the invention encompasses above all those mixtures which, on the one hand, meet the viscosity requirement according to the invention and of which, on the other hand, at least 50% comprise the monofunctional esters of the olefinically mono- and/or polyunsaturated C 16-24 carboxylic acids. Ester constituents and, in particular, carboxylic acid esters or monofunctional alcohols and monofunctional carboxylic acids of different constitution may be present as minor constituents of the mixture providing the mixture has the required property profile. This is important where carboxylic acid mixtures of natural origin are used. Natural starting materials such as these generally also contain more or less large proportions of saturated carboxylic acids, often including linear C 16-18 carboxylic acids. Saturated fatty acids of this type and their esters readily give rise to rheologic difficulties due to their comparatively high melting points. According to the invention, therefore, saturated C 16-18 is carboxylic acids preferably make up no more than 20% by weight and, in particular, no more than 10% by weight of the ester oils. By contrast, the presence of saturated carboxylic acids containing less than 16 carbon atoms and, more especially, from 12 to 14 carbon atoms is more acceptable. In small quantities, the contents of such lower, fully saturated fatty acids often present in natural starting materials are frequently valuable mixture components in the context of the problem addressed by the invention. Their esters are not vulnerable to oxidation under practical inuse conditions and their rheologic properties promote the objective of the invention, namely to replace the pure hydrocarbon oils hitherto solely used in practice by ester oils or ester oil fractions. The alcohol radicals or the esters or ester mixtures according to the invention are preferably derived from straight-chain and/or branched-chain saturated alcohols, particular significance being attributed to alcohols containing at least 3 C atoms and, more especially, to alcohols containing up to about 10 C atoms. The alcohols can also be of natural origin, in which case they have normally been obtained from the corresponding carboxylic acids or their esters by hydrogenating reduction. However, the invention is by no means limited to starting materials of natural origin. Both on the monoalcohol side and on the monocarboxylic acid side, the starting materials of natural origin may be partly or completely replaced by corresponding components of synthetic origin. Typical examples of alcohols are the corresponding oxo alcohols (branched alcohols) and the linear alcohols obtained by the Ziegler process. Similarly, monocarboxylic acid components present in particular in carboxylic acid mixtures can be derived from petrochemical synthesis. However, the advantages of starting materials of natural origin lie in particular in their proven lower toxicologic values, their ready degradability and their ready accessibility. The natural destruction of the used oil mud ultimately required presupposes that ester oils of the type described herein be both aerobically and anaerobically degradable. However, one important limitation is associated with the use of these ester oils in invert oil muds of the type used in the present invention. This limitation arises out of the difficulty mentioned at the beginning that, in principle, the carboxylic acid esters are vulnerable to hydrolysis and, accordingly, have to behave differently than the pure hydrocarbon oils hitherto used. Invert drilling muds of the type used herein contain the finely disperse aqueous phase, normally together with the continuous oil phase, in quantities of from 5 to 45% by weight and preferably in quantities of from 5 to 25% by weight. Particularly preferred is the range of 10 to 25% by weight of disperse aqueous phase. This pre-condition from the constitution of conventional drilling muds also applies to the ester-based invert drilling muds of the invention. It is clear that, in continuous practical operation, disturbances of the equilibrium can occur in the multiphase system as a result of partial ester hydrolysis. The situation is complicated by the fact that, in practice, drilling muds of the present type always contain an alkali reserve. This alkali reserve is particularly important in affording protection against corrosion caused by unexpected inrushes of acidic gases, particularly CO 2 and/or H 2 S. The danger of corrosion to the drill pipe requires the safe establishment of pH values at least in the mildly alkaline range, for example in the range from pH 8.5 to 9 and higher. In oil muds based on pure hydrocarbon fractions as the oil phase, strongly alkaline and, at the same time, highly hydrophilic inorganic or organic additives are generally used in practice without any difficulty. Particular significance can be attributed to the alkali hydroxides and, in particular, to sodium hydroxide on the one hand or to highly hydrophilic organic bases, diethanolamine and/or triethanolamine being particularly typical additives for binding impurities of H 2 S. In addition to and/or instead of the highly hydrophilic inorganic and organic bases mentioned here, lime or even more weakly basic metal oxides, especially zinc oxide or comparable zinc compounds, are particularly important as the alkali reserve. Lime in particular is widely used an inexpensive alkalizing agent. It may safely be used in comparatively high quantities of, for example, from 5 to 10 lb/bbl (lime/oil mud) or even higher. The use of the ester-based oil muds of the invention requires a departure from standard practice so far as these variables are concerned. It is of course necessary in this case, too, to ensure that the pH value of the drilling mud is kept at least in the mildly alkaline range and that a sufficient quantity of alkali reserve is available for unexpected inrushes of, in particular, acidic gases. At the same time, however, the ester hydrolysis should not be undesirably promoted and/or accelerated by such an alkali content. Thus, in the preferred embodiment of the invention, no significant quantities of highly hydrophilic, inorganic and/or organic bases are used in the oil mud. In particular, the invention does not use alkali hydroxides or highly hydrophilic amines of the diethanolamine and/or triethanolamine type. Lime may be effectively used as the alkali reserve. In that case, however, it is best to limit the maximum quantity of lime used in the drilling mud to around 2 lb/bbl or slightly lower, for example to between 1 and 1.8 lb/bbl (lime/drilling mud). In addition to or instead of lime, it is also possible to use other known alkali reserves, including in particular the less basic metal oxides of the zinc oxide type and other comparable zinc compounds. However, even where acid-binding agents such as these are used, it is important not to use excessive amounts to prevent unwanted premature ageing of the drilling mud accompanied by an increase in viscosity and hence a deterioration in the rheologic properties. The particular aspect of the teaching according to the invention prevents or at least limits the formation of unwanted quantities of highly active o/w emulsifiers to such an extent that the favorable rheologic properties are maintained for long periods in operation, even in the event of thermal ageing. In relation to the recommendations of the prior art which have hitherto remained in the realm of theoretical considerations, this represents a significant surplus which actually enables the low toxic properties of ester oils of the present type to be utilized in practice for the first time. The esters based on olefinically unsaturated C 16-24 monocarboxylic acids defined in accordance with the invention, which flow and can be pumped at temperatures in the range from 0° to 5° C., generally make up at least about half the continuous oil phase of the drilling mud. However, preferred oil phases are those in which esters or ester mixtures of the type according to the invention are very much predominantly present. In one particularly important embodiment of the invention, the oil phase consists almost entirely of such ester oils. Components suitable for mixing with the ester oils defined in accordance with the invention are, in particular, selected other ester oil fractions which are described in U.S. Ser. No. 07/452,988 now abandoned "Drilling Fluids and Muds Containing Selected Ester Oils"), filed of even data herewith. The invention also encompasses mixtures with such other selected ester oils. These ester oils, which are described in the above copending application, incorporated herein by reference, are esters of monofunctional C 2-12 alcohols and saturated aliphatic C 12-16 monocarboxylic acids. The following rheologic data apply to the rheology of preferred invert drilling muds according to the invention: plastic viscosity (PV) in the range of from 10 to 60 mPa.s and preferably in the range of from 15 to 40 mPa.s, yield point (YP) in the range of from 5 to 40 lb/100 ft 2 and preferably in the range of from 10 to 25 lb/100 ft 2 , as measured at 50° C. Full information on the determination of these parameters, on the measurement techniques used and on the otherwise standard composition of the invert oil muds described herein can be found in the prior art cited above and, for example, in "Manual of Drilling Fluids Technology" published by BAROID DRILLING FLUIDS, INC., cf. in particular the Chapter entitled "Mud Testing--Tools and Techniques" and "Oil Mud Technology", which is freely available to interested experts. In the interests of fullness of disclosure, the following summary observations may be made: Emulsifiers suitable for use in practice are systems which are capable of forming the required w/o emulsions. Selected olephilic fatty acid salts, for example those based on amidoamine compounds, are particularly suitable, examples being described in the already cited U.S. Pat. No. 4,374,737 and the literature cited therein. One particularly suitable type of emulsifier is the product marketed under the name of "EZ-MUL™" by BAROID DRILLING FLUIDS, INC. Emulsifiers of the above type are marketed in the form of concentrate and can be used, for example, in quantities of from 2.5 to 5% by weight and more especially in quantities of from 3 to 4% by weight, based in each case of the ester oil phase. In practice, organophilic lignite is used as a fluid-loss additive and forms an impervious coating in the form of a substantially water-impermeable film over the walls of the well. Suitable quantities are, for example, in the range of from 15 to 20 lb/bbl or in the range of from 5 to 7% by weight, based on the ester oil phase. In drilling muds of the present type, the thickener normally used to create viscosity is a cationically modified, finely divided organophilic bentonite which can be used in quantities of from 8 to 10 lb/bbl or in the range of from 2 to 4% by weight, based on the ester oil phase. The weighing agent normally used in practice to establish the necessary pressure equalization is barite which is added in quantities adapted to the particular conditions to be expected in the well. For example, it is possible by addition of barite to increase the specific gravity of the drilling mud to values of up to about 2.5 and preferably in the range from 1.3 to 1.6. In invert drilling muds of the present type, the disperse aqueous phase is charged with soluble salts, generally calcium chloride and/or potassium chloride, the aqueous phase preferably being saturated with the soluble salt at room temperature. The emulsifiers or emulsifier systems mentioned above can also be used to improve the oil wettability of the inorganic weighting materials. In addition to the aminoamides already discussed, alkyl benzensulfonates and imidazoline components are further examples. Additional information on the relevant prior art can be found in the following literature references: GB 2,158,437, EP 229 912 and DE 32 47 123. One important application for the new drilling fluids is in offshore drilling for the development of oil and/or gas sources, to provide technically useful drilling fluids of high ecological compatibility. The use of the new drilling fluids is of particular importance in, but is not limited to, the offshore sector. The new drilling fluids can also be used quite generally for land-supported drilling, including for example geothermal drilling, water drilling, geoscientific drilling and mine drilling. In this case, too, the ester-based drilling fluids selected in accordance with the invention basically simplify ecotoxic problems to a considerable extent. In addition, the drilling fluids based in accordance with the invention on the co-use of ester oils of the described type are also distinguished by distinctly improved lubricity. This is particularly important when the path of the drill pipe and hence the well deviate from the vertical during drilling, for example at considerable depths. In such cases, the rotating drill pipe readily comes into contact with the well wall and embeds itself therein. Ester oils of the type used as oil phase in accordance with the invention have a distinctly better lubricating effect than the mineral oils hitherto used, which is an important advantage of the present invention. The invention will be illustrated but not limited by the following examples. EXAMPLES EXAMPLE 1 An invert drilling mud was prepared using an undistilled isobutyl rapeseed oil ester at the continuous oil phase. This rapeseed ester was based on a mixture of predominantly unsaturated, straight-chain carboxylic acids which correspond substantially to the following distribution; 60% oleic acid, 20% linoleic acid, 9 to 10% linolenic acid, olefinically unsaturated C 20-22 monocarboxylic acids approximately 4% remainder saturated monocarboxylic acids predominantly in the C 16-18 range. The rapeseed oil ester used had the following characteristic data: density (20° C.) 0.872 g/cm 3 ; pour point below -15° C.; flash point (DIN 51584) above 180° C.; acid value (DGF-C-V 2) 1.2; viscosity at 0° C. 32 mPa.s, viscosity at 5° C. 24 mPa.s; no aromatic compounds. An invert drilling mud was conventionally prepared using the following mixture constituents: ______________________________________230 ml rapeseed oil fatty acid ester26 ml water6 g organophilic bentonite (GELTONE ™, a product of BAROID DRILLING FLUIDS, INC. of Aberdeen, Scotland)0.2 g line6 g water in oil emulsifier ("EZ-MUL ™", a product of BAROID DRILLING FLUIDS, INC.)340 g basis9.2 g CaCl.sub.2 × 2H.sub.2 O20 g organophilic lignite ("DURATONE ™", a product of BARIOD DRILLING FLUIDS. INC.)______________________________________ Plastic viscosity (PV), yield point (YP) and gel strength after 10 seconds and 10 minutes were first determined on the material before ageing by viscosity measurement at 50° C. The invert drilling mud was then aged for 16 h at 125° C. in an autoclave in a so-called "roller oven" to determine the effect of temperature on the stability of the emulsion. The viscosity values were redetermined at 50° C. The following results were obtained: ______________________________________ Unaged Aged material material______________________________________Plastic viscosity (PV) 35 62Yield point (YP) 21 24Gel strength (lb/100 ft.sup.2)10 seconds 12 1210 minutes 14 15______________________________________ COMPARISON EXAMPLE 1 Another invert drilling mud was prepared in the same way as in Example 1, except that on this occasion the quantity of lime was increased to 4 g, i.e. drastically beyond the limit of approximately 2 lb/bbl. Once again, the viscosity values and gel strength of the material were determined before and after ageing. The following results were obtained: ______________________________________ Unaged Aged material material______________________________________Plastic viscosity (PV) 41 cannot be measuredYield point (YP) 22 cannot be measuredGel strength (lb/100 ft.sup.2)10 seconds 11 7410 minutes 17 72______________________________________ EXAMPLE 2 Another invert drilling mud was prepared with a continuous oil phase. The oil phase consisted of distilled oleic acid isobutyl ester which has the following characteristic data: density (20° C.) 0.86 gg/cm 3 ; viscosity (20° C.) 8 to 10 mPa.s; pour point below -25° C.; flash point (51584) above 185° C.; acid value (DGF)-CV 2) below 1; no aromatic compounds. A drilling mud of the following composition was prepared: ______________________________________210 ml isobutyl oleate6 g fatty-acid-based emulsifier (INVERMUL ™, a product of BAROID DRILLING FLUIDS, INC.)6 g organophilic bentonite (GELTONE II ™, a product of BAROID DRILLING FLUIDS, INC.)13 g organophilic lignite (DURATONE ™, a product of BAROID DRILLING FLUIDS, INC.)1 g lime3 g water in oil emulsifier (EZ-MUL ™, a product of BAROID DRILLING FLUIDS, INC.)270 g barite58.2 g saturated aqueous CaCl.sub.2 solution______________________________________ Plastic viscosity, yield point and gel strength after 10 seconds and 10 minutes were determined before and after ageing (16 h at 125° C. in a roller oven) in the same way as in Example 1. The results obtained are shown below. In the formulation used here, . .1.2 kg.!. .Iadd.1.9 g .Iaddend.lime substantially corresponds to the limit of 2 lb/bbl. ______________________________________ Unaged Aged material material______________________________________Plastic viscosity (PV) 46 41Yield point (YP) 35 32Gel strength (lb/100 ft.sup.2)10 seconds 17 1810 minutes 21 29______________________________________ . .COMPARISON.!. EXAMPLE . .2.!. .Iadd.3 .Iaddend. Another invert drilling oil emulsion was prepared using the formulation of Example 2, except that the addition of lime was increased to 2 g and hence to . .clearly beyond.!. .Iadd.within .Iaddend.the limit of .Iadd.about .Iaddend.2 lb/bbl. The plastic viscosity, yield point and gel strength of the material before and after ageing are shown in the following: ______________________________________ Unaged Aged material material______________________________________Plastic viscosity (PV) 33 46Yield point (YP) 61 45Gel strength (lb/100 ft.sup.2)10 seconds 33 2410 minutes 40 29______________________________________
Invert emulsion muds for drilling of gas and oil, which are environmentally safe, and which contain: A. a continuous oil phase composed predominantly of at least one monocarboxylic acid ester of a C 2 -C 12 monofunctional alkalol wherein the monocarboxylic acid contains from 16 to 24 carbon atoms and is olefinically mono- or poly-unsaturated, B. a disperse aqueous phase, C. at least one emulsifier, D. at least one weighing agent, E. at least one fluid loss additive, and F. a mild alkaline reserve.
2
CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 62/154,090, filed on Apr. 28, 2015, which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a communication device and a method used in a wireless communication system, and more particularly, to a communication device and method of reporting a buffer status report in a wireless communication system. [0004] 2. Description of the Prior Art [0005] Long-term evolution (LTE)/Wireless Local Area Network (WLAN) aggregation can be used for increasing data rate. A user equipment (UE) provides a buffer status report (BSR) indicating an amount of buffered data available for transmission to the eNB, such that the eNB can schedule UL grant (s) (e.g., for allocation of LTE resource (s)) to the UE according to the amount. SUMMARY OF THE INVENTION [0006] The present invention therefore provides a method and related communication device for reporting a buffer status report to solve the abovementioned problem. [0007] A communication device for reporting a buffer status report (BSR) to a base station (BS) comprises a storage unit for storing instructions and a processing means coupled to the storage unit. The processing means is configured to execute the instructions stored in the storage unit. The instructions comprise being configured a first radio bearer (RB) utilizing wireless local area network (WLAN) resources; and transmitting the BSR to the BS, wherein the BSR excludes an amount of buffered data of the first RB. [0008] A base station (BS) for scheduling a communication device comprises a storage unit for storing instructions and a processing means coupled to the storage unit. The processing means is configured to execute the instructions stored in the storage unit. The instructions comprise configuring a first radio bearer (RB) utilizing wireless local area network (WLAN) resources for data transmission to the communication device; configuring a second RB utilizing long-term evolution (LTE) resources for the data transmission to the communication device; and configuring the communication device not to report a buffer size indicating a sum of an amount of buffered data of the first RB and an amount of buffered data of the second RB in a buffer status report (BSR). [0009] A communication device for triggering a buffer status report (BSR) to a base station (BS) comprises a storage unit for storing instructions and a processing means coupled to the storage unit. The processing means is configured to execute the instructions stored in the storage unit. The instructions comprise being configured a first radio bearer (RB) utilizing wireless local area network (WLAN) resources and long-term evolution (LTE) resources; transmitting the BSR to the BS, if an amount of buffered data of the first RB is larger than a threshold; and not transmitting the BSR to the BS, if the amount of the buffered data of the first RB is smaller than the threshold. [0010] A communication device for triggering a buffer status report (BSR) to a base station (BS) comprises a storage unit for storing instructions and a processing means coupled to the storage unit. The processing means is configured to execute the instructions stored in the storage unit. The instructions comprise being configured at least one radio bearer (RB) utilizing wireless local area network (WLAN) resources and long-term evolution (LTE) resources; triggering the BSR to the BS, wherein the BSR indicating an amount of buffered data of the at least one RB; and cancelling the triggered BSR, if the communication device transmits all of the buffered data via the WLAN resources. [0011] A base station (BS) for scheduling a communication device comprises a storage unit for storing instructions and a processing means coupled to the storage unit. The processing means is configured to execute the instructions stored in the storage unit. The instructions comprise configuring at least one radio bearer (RB) utilizing wireless local area network (WLAN) resources and long-term evolution (LTE) resources for data transmission to the communication device; receiving a buffer status report (BSR) indicating a buffer size indicating an amount of buffered data of the at least one RB from the communication device; transmitting an uplink (UL) grant to the communication device, if the amount of the buffered data of the at least one RB is larger than a threshold; and not transmitting the UL grant to the communication device, if the amount of the buffered data of the at least one RB is smaller than the threshold. [0012] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a schematic diagram of a wireless communication system according to an example of the present invention. [0014] FIG. 2 is a schematic diagram of a communication device according to an example of the present invention. [0015] FIG. 3 is a flowchart of a process according to an example of the present invention. [0016] FIG. 4 is a flowchart of a process according to an example of the present invention. [0017] FIG. 5 is a flowchart of a process according to an example of the present invention. [0018] FIG. 6 is a flowchart of a process according to an example of the present invention. [0019] FIG. 7 is a flowchart of a process according to an example of the present invention. DETAILED DESCRIPTION [0020] FIG. 1 is a schematic diagram of a wireless communication system 10 according to an example of the present invention. The wireless communication system 10 is briefly composed of a communication device 100 , a base station (BS) 102 and an access point (AP) 104 . In FIG. 1 , the communication device 100 , the BS 102 and AP 104 are simply utilized for illustrating the structure of the wireless communication system 10 . In one example, the BS 102 may be an evolved Node-B (eNB) in an evolved universal terrestrial radio access network (UTRAN) (E-UTRAN) of a long term evolution (LTE) system, or a fifth generation (5G) BS employing orthogonal frequency-division multiplexing (OFDM) and/or non-OFDM for communicating with the communication device 100 in a wider bandwidth (e.g., greater than 20 MHz) or a shorter time interval (e.g., less than 1 ms) of transmission. The AP 104 may be a network entity in a wireless local area network (WLAN). The communication device 100 and the AP 104 may support IEEE 802.11 related standards (e.g., IEEE 802.11a/b/g/n/ac/ad). [0021] In FIG. 1 , the communication device 100 may be configured to communicate with the BS 102 and AP 104 at the same time according to LTE/WLAN aggregation or 5G/WLAN aggregation configured to the communication device 100 . That is, the communication device 100 may perform a transmission/reception via both the BS 102 and the AP 104 . In addition, the communication device 100 may communicate with the BS 102 via one or more radio bearer(s) utilizing the LTE or 5G resource(s), and the communication device 100 may communicate with the AP 104 via one or more radio bearer(s) utilizing the WLAN resource(s). [0022] The communication device 100 may be an user equipment (UE), a mobile phone, a laptop, a tablet computer, an electronic book, a portable computer system, a vehicle or an aircraft. In addition, for an uplink (UL), the communication device 100 is a transmitter and the BS 102 and AP 104 are receivers, and for a downlink (DL), the BS 102 and AP 104 are transmitters and the communication device 100 is a receiver. [0023] FIG. 2 is a schematic diagram of a communication device 20 according to an example of the present invention. The communication device 20 may be the communication device 100 , the BS 102 or the AP 104 shown in FIG. 1 , but is not limited herein. The communication device 20 may include a processing means 200 such as a microprocessor or Application Specific Integrated Circuit (ASIC), a storage unit 210 and a communication interfacing unit 220 . The storage unit 210 may be any data storage device that may store a program code 214 , accessed and executed by the processing means 200 . Examples of the storage unit 210 include but are not limited to a read-only memory (ROM), flash memory, random-access memory (RAM), hard disk, optical data storage device, non-volatile storage unit, non-transitory computer-readable medium (e.g., tangible media), etc. The communication interfacing unit 220 is preferably a transceiver and is used to transmit and receive signals (e.g., data, messages and/or packets) according to processing results of the processing means 200 . [0024] In the following embodiments, a UE is used to represent the communication device 100 in FIG. 1 and a BS is used to represent the BS 102 in FIG. 1 to simplify the illustration of the embodiments. [0025] FIG. 3 is a flowchart of a process 30 according to an example of the present invention. The process 30 may be utilized in a UE, to report a buffer status report (BSR) to a BS. The process 30 includes the following steps: [0026] Step 300 : Start. [0027] Step 302 : Be configured a first radio bearer (RB) utilizing WLAN resources. [0028] Step 304 : Transmit the BSR to the BS, wherein the BSR excludes an amount of buffered data of the first RB. [0029] Step 306 : End. [0030] According to the process 30 , the UE may be configured a first RB utilizing WLAN resources. Then, the UE may transmit the BSR to the BS, wherein the BSR may exclude an amount of buffered data of the first RB. That is, the UE may not transmit the amount of the buffered data of the first RB to the BS. Accordingly, the BS may not waste resource(s) of the LTE by overscheduling UL grant(s) to accommodate the amount of the buffered data to the UE, because the UE excludes the amount of the buffered data of the first RB from the BSR. Thus, the problem of overscheduling is solved. As a result, not only resource(s) of the LTE can be used effectively, but also the benefit of the LTE/WLAN aggregation can be maintained. [0031] Realization of the process 30 is not limited to the above description. [0032] The following example is used for illustrating the process 30 . The UE may have a radio resource control (RRC) connection with the BS. That is, the UE may have a signaling RB (SRB) with the BS, and may be in the RRC connected mode. Then, the BS may transmit a RRC message configuring a first RB utilizing only WLAN resources to the UE. In addition, the UE determines to transmit a BSR to the BS due to a triggering condition is satisfied. The UE excludes an amount of buffered data of the first RB, if the UE has data of the first RB in the buffer. The triggering condition may be an availability for data transmission of the first RB or a second RB, an expiry of a periodic BSR timer (e.g., periodicBSR-Timer), an expiry of a retransmission BSR timer (e.g., retxBSR-Timer) or a padding BSR. The BS may configure the SRB and/or the second RB utilizing only the LTE or both the LTE and the WLAN. The BSR may include an amount of buffered data of the SRB and an amount of buffered data of the second RB. [0033] The UE may not determine to transmit the BSR to the BS, when the data of the first RB becomes available for transmission rather than the data of the SRB or the second RB becomes available for transmission. In other words, the BSR may not be triggered by the data of the first RB which becomes available for transmission, and the BSR may only be triggered by the data of the SRB or the second RB which becomes available for transmission. Furthermore, the BS may configure the UE to exclude the amount of the buffered data of the first RB from the BSR by using the RRC message. That is, the UE may not transmit a buffer size indicating a sum of the amount of the buffered data of the first RB and an amount of buffered data of the second RB and/or SRB. The BS may transmit UL grants accommodating transmission of amount of data excluding the amount of the buffered data of the first RB to the UE, if the BS configures the UE to include the amount of the buffered data of the first RB. For example, the BS may receive the BSR indicating that there are about 100 bytes buffered data of the first RB, and there are about 200 bytes buffered data of the second RB. The BS may schedule the UL grant(s) accommodating about 200 bytes buffered data of the second RB to the UE, but may not schedule the UL grant (s) accommodating about 100 bytes buffered data of the first RB to the UE. [0034] FIG. 4 is a flowchart of a process 40 according to an example of the present invention. The process 40 may be utilized in a BS scheduling a UE. The process 40 includes the following steps: [0035] Step 400 : Start. [0036] Step 402 : Configure a first RB utilizing WLAN resources for data transmission to the UE. [0037] Step 404 : Configure a second RB utilizing LTE resources for the data transmission to the UE. [0038] Step 406 : Configure the UE not to report a buffer size indicating a sum of an amount of buffered data of the first RB and an amount of buffered data of the second RB in a BSR. [0039] Step 408 : End. [0040] According to the process 40 , the BS configure a first RB utilizing WLAN resources for data transmission and a second RB utilizing LTE resources for the data transmission to the UE. Then, the BS configures the UE not to report a buffer size indicating a sum of an amount of buffered data of the first RB and an amount of buffered data of the second RB in a BSR. That is, the UE transmits the BSR not including the buffer size indicating the sum of the amount of the buffered data of the first RB and the amount of the buffered data of the second RB to the BS. The BSR may include a first buffer size indicating the amount of the buffered data of the first RB and/or a second buffer size indicating the amount of the buffered data of the second RB. Accordingly, the BS may not transmit UL grant(s) accommodating the sum of the amount of the buffered data of the first RB and the amount of the buffered data of the second RB to the UE. The BS may transmit UL grant(s) accommodating the amount of the buffered data of the second RB according to the second buffer size but does not transmit UL grant(s) accommodating the amount of the buffered data of the first RB. [0041] Realization of the process 40 is not limited to the above description. The following examples are used for illustrating the process 40 . [0042] In one example, the UE may have a RRC connection with the BS. That is, the UE may have a SRB with the BS and may be in the RRC connected mode. Then, the BS may transmit a first RRC message configuring a first RB utilizing only WLAN resources to the UE, and may transmit a second RRC message configuring a second RB utilizing LTE resources to the UE. In addition, the BS may configure the UE not to report a buffer size indicating a sum of an amount of buffered data of the first RB and an amount of buffered data of the second RB by using the first RRC message. Thus, the UE may transmit a BSR not including the buffer size indicating the sum of the amount of the buffered data of the first RB and the amount of the buffered data of the second RB to the BS. [0043] In one example, the BS may configure that the first RB belongs to a first logical channel group (LCG) to the UE, and may configure that the second RB belongs to a second LCG to the UE, wherein the first and the second LCGs are different LCGs. In other words, the first LCG may include RB(s) utilizing only WLAN resources for data transmission, and the second LCG may not include RB (s) utilizing only the WLAN resources for the data transmission. Thus, the UE may transmit the BSR not including the buffer size indicating the sum of the amount of the buffered data of the first RB and the amount of the buffered data of the second RB to the BS. The BSR may include the first buffer size of the first LCG and the second buffer size of the second LCG. For example, the first buffer size may indicate 100 bytes buffered data of the first LCG and the second buffer size may indicate 200 bytes buffered data of the second LCG. [0044] Further, the UE may transmit the BSR when the amount of the buffered data of the first RB (or an index of the amount of the buffered data of the first RB) is larger than (i.e., above) a threshold. The BS may configure the threshold. For example, the UE may transmit the BSR when the UE detects the amount of the buffered data of the first RB is larger than 150 bytes or the index of the amount of the buffered data of the first RB is larger than an index 19 . In another example, the BS may configure the UE to transmit a BSR, if the amount of the buffered data of the RB(s) (or an index of the amount of the buffered data of the RB(s)) belonging to the first LCG is larger than (i.e., above) a threshold. All the RB(s) belonging to the first LCG may utilize the WLAN resources. [0045] Furthermore, the BS may configure the UE not to transmit a scheduling request (SR) (i.e., SR prohibition) for a transmission of a BSR triggered by data transmission of the first RB available for transmission. That is, the UE is not allowed to transmit the SR for the transmission of the BSR. [0046] In one example, the BS may configure that the first RB does not belong to any one of LCGs to the UE. Thus, the UE does not includes the buffer size indicating the sum of the amount of the buffered data of the first RB and the amount of the buffered data of the second RB in any BSR transmitted to the BS. In addition, the UE does not trigger any BSR reporting due to that data of the first RB becomes available for transmission. [0047] In general, the BS should not configure a RB utilizing only the WLAN resources and another RB utilizing the LTE resources to be in the same LCG. [0048] FIG. 5 is a flowchart of a process 50 according to an example of the present invention. The process 50 may be utilized in a UE, to trigger a BSR to a BS. The process 50 includes the following steps: [0049] Step 500 : Start. [0050] Step 502 : Be configured a first RB utilizing WLAN resources and LTE resources. [0051] Step 504 : Transmit a BSR to the BS, if an amount of buffered data of the first RB is larger than a threshold. [0052] Step 506 : Not transmit the BSR to the BS, if the amount of the buffered data of the first RB is smaller than the threshold. [0053] Step 508 : End. [0054] According to the process 50 , the UE is configured a first RB utilizing WLAN resources and LTE resources. Then, the UE transmits (e.g., trigger) a BSR to the BS, if an amount of buffered data of the first RB is larger than a threshold, but the UE does not transmit (e.g., trigger) the BSR to the BS, if the amount of the buffered data of the first RB is smaller than the threshold. [0055] Realization of the process 50 is not limited to the above description. The following examples are used for illustrating the process 50 . [0056] In one example, the UE has a RRC connection with the BS. That is, the UE has a SRB with the BS, and is in the RRC connected mode. Then, the BS transmits at least one RRC message configuring a first RB utilizing both the WLAN resources and LTE resources to the UE. The UE determines to transmit the BSR to the BS, if the UE has data of the first RB available in the buffer, and the amount of the buffered data of the first RB is larger than a threshold. The BSR may include a buffer size considering the amount of the buffered data of the first RB, or include a buffer size only considering the difference between the amount of the buffered data of the first RB and the threshold (i.e., the amount of the buffered data of the first RB−the threshold). Thus, the BS may transmit UL grant(s) accommodating the less amount of the buffered data of the first RB to the UE. [0057] In one example, the threshold is configured by a RRC message transmitted by the BS. In another example, the UE may or may not transmit the BSR to the BS, if the amount of the buffered data of the first RB is equal to the threshold. [0058] In one example, the UE has the amount of the buffered data of the first RB is 1000 bytes, which is larger than the threshold configured with 500 bytes. Thus, the UE transmits the BSR including an index indicating 1000 bytes or 500 bytes to the BS. In one example, the BSR includes an index indicating 1300 bytes or 800 bytes, if a second RB or the SRB has 300 bytes buffered data available for the transmission and the second RB and the first RB belong to a same LCG. The second RB or the SRB utilizes only the LTE resources. In another example, the UE has the amount of the buffered data of the first RB is 400 bytes, which is smaller than the threshold configured with 500 bytes. Thus, the UE does not transmit the BSR to the BS. [0059] In one example, the UE triggers transmission of the BSR, if 300 bytes data of the SRB becomes available, and the UE has 700 bytes data of the first DRB in the buffer. The UE may generate the BSR including a first index indicating the 300 bytes and a second index indicating the 700 bytes or 200 bytes, because the amount of the buffered data of first RB (i.e., 700 bytes) is larger than the threshold (i.e., 500 bytes) or an index of 700 bytes (e.g. 28) is larger than the threshold (e.g., 26). Because the UE may transmit part of the amount of the buffered data of the first RB (i.e., 700 byte) (e.g., 300 bytes or 500 bytes) via the WLAN, the BS may transmit the uplink grant(s) accommodating less than 700 bytes, if the BSR includes the second index indicating the amount of the buffered data of first RB (i.e., 700 byte). [0060] In one example, the BS configures the threshold with a larger value, if the BS allows the UE to transmit more data via the WLAN resources. In one example, the BS configures the threshold with a great value (e.g., infinity) to avoid the UE triggering the BSR including the buffer status of the RB utilizing the WLAN resources. [0061] Furthermore, the UE may trigger transmitting a BSR to the BS, when an amount of the buffered data of the RB is larger than a threshold. The UE may cancel the triggered BSR, because an amount of the buffered data of the RB becomes smaller (e.g., smaller than the threshold) due to that the UE transmits part or all of the buffered data via the WLAN resources before transmitting the BSR. [0062] FIG. 6 is a flowchart of a process 60 according to an example of the present invention. The process 60 may be utilized in a UE, to trigger a BSR to a BS. The process 60 includes the following steps: [0063] Step 600 : Start. [0064] Step 602 : Be configured at least one RB utilizing WLAN resources and LTE resources. [0065] Step 604 : Trigger a BSR to the BS, wherein the BSR indicating an amount of buffered data of the at least one RB. [0066] Step 606 : Cancel the triggered BSR, if the UE transmits all of the buffered data via the WLAN resources. [0067] Step 608 : End. [0068] According to the process 60 , the UE may be configured at least one RB utilizing WLAN resources and LTE resources. Then, the UE may trigger a BSR to the BS, wherein the BSR indicating an amount of buffered data of the at least one RB. The UE may cancel the triggered BSR, if the UE transmits all of the buffered data via the WLAN resources. That is, although the BSR is triggered, it still can be cancelled if all of the buffered data has been transmitted by the UE via the WLAN resources. [0069] The following example is used for illustrating to clarify the process 60 . The UE may have a RRC connection with the BS. That is, the UE may have a SRB with the BS, and may be in the RRC connected mode. Then, the BS may transmit at least one RRC message configuring at least one RB utilizing both the WLAN resources and LTE resources to the UE. The UE may determine to transmit the BSR to the BS, if the UE has data of the at least one RB available in the buffer. The UE may cancel the triggered BSR, because the UE transmits all of the buffered data via the WLAN resources before transmitting the BSR, i.e., there is no buffered data to be reported. [0070] FIG. 7 is a flowchart of a process 70 according to an example of the present invention. The process 70 may be utilized in a BS, to schedule a UE. The process 70 includes the following steps: [0071] Step 700 : Start. [0072] Step 702 : Configure at least one RB utilizing WLAN resources and LTE resources for data transmission to the UE. [0073] Step 704 : Receive a BSR indicating a buffer size indicating an amount of buffered data of the at least one RB from the UE. [0074] Step 706 : Transmit an UL grant to the UE, if the amount of the buffered data of the at least one RB is larger than a threshold. [0075] Step 708 : Not transmit the UL grant to the UE, if the amount of the buffered data of the at least one RB is smaller than the threshold. [0076] Step 710 : End. [0077] According to the process 70 , the BS configures at least one RB utilizing WLAN resources and LTE resources for data transmission to the UE. Then, the BS receives a BSR indicating an amount of buffered data of the at least one RB from the UE. The BS transmits an UL grant to the UE, if the amount of the buffered data of the at least one RB is larger than a threshold but does not transmit the UL grant to the UE, if the amount of the buffered data of the at least one RB is smaller than the threshold. The BS configures the threshold with a larger value, if the BS allows the UE to transmit more data via the WLAN resources. Accordingly, the BS may not transmit UL grant(s) accommodating an amount of buffered data of all of the at least one RB. [0078] It should be noted that although the above examples are illustrated to clarify the related operations of corresponding processes. The examples can be combined and/or modified arbitrarily according to system requirements and/or design considerations. In one example, the RB may be a data radio bearer (DRB), and the RRC message may be an RRCConnectionReconfiguration message. The term “resources” may represent a plurality of durations (e.g. OFDM/non-OFDM symbols, time slots, subframes or frames) and/or frequency(ies) (e.g. subcarrier(s) or carrier(s)). [0079] Those skilled in the art should readily make combinations, modifications and/or alterations on the abovementioned description and examples. Any of the abovementioned processes may be compiled into the program code 214 . The abovementioned description, steps and/or processes including suggested steps can be realized by means that could be hardware, software, firmware (known as a combination of a hardware device and computer instructions and data that reside as read-only software on the hardware device), an electronic system, or combination thereof. An example of the means may be the communication device 20 . [0080] To sum up, the present invention provides a method and related communication device for reporting a BSR to a BS. Accordingly, the BS may not waste resource(s) of the LTE by overscheduling UL transmission(s) to the communication device. Thus, the problem that resource(s) of the LTE are not used efficiently is solved. [0081] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.
A communication device for reporting a buffer status report (BSR) to a base station (BS) comprises a storage unit for storing instructions and a processing means coupled to the storage unit. The processing means is configured to execute the instructions stored in the storage unit. The instructions comprise being configured a first radio bearer (RB) utilizing wireless local area network (WLAN) resources; and transmitting the BSR to the BS, wherein the BSR excludes an amount of buffered data of the first RB.
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TECHNICAL FIELD This invention relates to recumbent bicycles and more particularly, to an improved rear wheel attachment method and improved pedal locating and adjustment method—both for recumbent bicycles or tricycles. BACKGROUND The recumbent bicycle and recumbent tricycle art is relatively young. As such, many inventors are experimenting with various methods of achieving optimized results associated with the industry in general. Recumbent bicycles and recumbent tricycles generally comprise a main frame coupled to a front wheel and a rear wheel or wheels with a seating area that places the rider in a supine position. In most prior art, the main frame includes a hollow center tube and a beam having a first end, and a second end coupled to the pedals of the recumbent. The first end of the beam commonly telescopes within the center tube to adjust the position of the pedals relative to the seating area to accommodate riders of different height. The beam is held in place within the center tube by a beam clamp. U.S. Pat. No. 8,342,555 reveals a recumbent tricycle typical of the industry with an adjustable pedal locating method. The pedal bearing assembly is attached to a tubular support piece that slides inside a coaxial tubular member attached to the primary bicycle frame. The pedal assembly is adjusted by loosening clamping bolts and sliding the pedal assembly further in or out of the support member attached to the primary bicycle in a telescopic fashion. U.S. Pat. No. 6,585,278 and WO 100015965 A2 both reveal recumbent bicycles typical of the industry with a front and rear-suspension. As can be seen, the assembly of the rear suspension requires components and, or frame design specific to the configuration depicted. Also shown is a similar pedal assembly adjustment method consisting of a pedal bearing assembly attached to a tubular support piece that slides inside a coaxial tubular member which is attached to the primary bicycle frame. U.S. Pat. No. 7,753,388 reveals a front-wheel powered recumbent bicycle which has a front wheel shock-absorber. Their invention is, in part, an approach to compensate for the variation of distance between the front wheel center and pedal sprocket center experienced as the front shock translates. The translational motion of the front shock increases or decreases the distance between the noted centers and causes reduced or increased chain tension in the process. If the position of the pedals is adjusted relative to the frame of the vehicle, it is often accomplished with the telescopic motion described above. Existing art, whether bicycle or tricycle, consist of generally similar rear wheel mounting methods. Typical mounting methods consist of permanently affixed primary frame appendages to which the wheel is attached with nut and bolt. Existing art with rear-suspensions generally consist of a frame assembly having front and rear portions connected at one or more pivot points with a shock absorber taking the load of the rider—see prior art. Front shock absorber translation is not typically a problem for chain tension considering the chain on a bicycle or tricycle is usually in the rear of the vehicle. In the prior art of front-wheel powered bicycles with front shock absorbers, the assembly of the front power train is allowed to flex such that chain tension is generally maintained. Panniers are often used on recumbent bicycles and tricycles with various attachment methods. The following is a list of a few disadvantages within the current art of recumbent bicycles and tricycles as it pertains to the invention described herein: 1) Prior art of adjustable pedal locating methods require a long internal telescoping tube for adjustment, and a long external support tube and does not maximize the adjustment possible for the amount of material used. 2) Prior art of rear suspension designs are relatively complicated, heavy, and do not take full advantage of existing technology. 3) Prior art of rear wheel attachment methods do not use existing front wheel attachment technology (such as forks, bearings, head-tubes, seals etc). This requires many unique parts. 4) Prior art of rear wheel attachment methods do not allow for flexibility in the owners choice of what type of rear wheel attachment may be used. 5) Prior art of rear wheel attachment methods do not allow for use of rigid or shock-absorber type forks interchangeably limiting performance under various riding conditions. BRIEF DESCRIPTION OF DRAWINGS NOTE: For simplicity of illustration, bearings, O-rings, nuts, bolts, washers and minutiae of common cycling industry hardware are not depicted as they are known to those with skill in the art. When they are shown, it is purely for illustrative purposes and not intended to capture all embodiments of the invention disclosed. FIG. 1 is a side view of a cyclist seated upon a recumbent bicycle having improved pedal locating and adjustment method, and improved real wheel attachment method. Both revealed in this invention. FIG. 2 is an enlarged perspective view of the bicycle of FIG. 1 with enhanced detail of the improved pedal locating and adjustment method, position adjustment, holes and screw. FIG. 3 is an enlarged side view of the pedal locating and adjustment method of FIG. 2 showing clamping bolts and position adjustment screw. FIG. 4 is an enlarged perspective exploded view of the pedal locating and adjustment method of FIG. 2 detached from support beam. Clamping bolts in exploded view, position adjustment bracket, and support beam leading to primary frame structure also in exploded view. FIG. 5 is comprised of three views of various pedal position adjustment methods, including a depiction wherein the pedals are attached to the support beam and the support beam translates through a handlebar mounted tube. FIG. 6 is comprised of two views of the real wheel attachment method herein revealed. One in perspective view, the other in profile and depicting angles of adjustment, fore and aft, 103 and 102 respectively. FIG. 7 is merely illustrative, and is comprised of an exploded view of the recumbent bicycle of FIG. 1 depicting two types of rear forks. FIG. 8 is comprised of several perspective and profile views of the primary frame member of recumbent bicycle revealed in FIG. 1 and is illustrative of various frame embodiments. FIG. 9 is comprised of two views, profile and perspective, of the recumbent bicycle in FIG. 1 depicting Panniers removeably attached to the primary frame member. FIG. 10 is comprised of two views of the detachable Pannier mounting method. FIG. 11 depicts a rear-wheel powered recumbent bicycle utilizing the improved pedal adjustment method of FIG. 2 with fairing attached. FIG. 12 is a profile view of the recumbent bicycle of FIG. 1 embodied with a chain tensioner mounted to the improved pedal adjustment method assembly of FIG. 2 . FIG. 13 is a view of an alternative embodiment of the adjustable pedal location assembly support member with a centrally located pivot that allows vertical height adjustment of the adjustable pedal location assembly. FIG. 14 is a perspective view of the recumbent bicycle in FIG. 1 having an alternative ‘under frame’ handlebar embodiment. FIG. 15 is a profile view of the recumbent bicycle in FIG. 1 having an alternative ‘under frame’ handlebar embodiment. FIG. 16 is a profile view of the recumbent bicycle in FIG. 1 having an alternative ‘tandem rider’ embodiment for two riders at the same time with both riders facing forward. FIG. 17 is a profile view of the recumbent bicycle in FIG. 1 having an alternative ‘tandem rider’ embodiment for two riders at the same time with one rider facing forward and the other rider facing aft, or in the reverse direction. FIG. 18 is a perspective view of an adjustable pedal assembly used for the tandem rider embodiments shown in FIG. 16 that is removable by removing the fasteners. FIG. 19 is an exploded perspective view of the adjustable pedal assembly shown in FIG. 18 . FIG. 20 illustrates how the revealed pedal location method, for the same amount of support material, advantageously increases the pedal adjustment distance. FIG. 21 is a perspective view of a tricycle embodiment utilizing on all three wheels bicycle forks only used on front wheels in existing art. Each rigid fork may be interchanged for shock-absorbing designs providing advantage to the owner with increased options. FIG. 22 is a perspective view of bicycle forks. FIG. 23 is a profile view of an alternative embodiment utilizing a support beam with a truss. DETAILED DESCRIPTION OF INVENTION The various embodiments and variations thereof illustrated in the accompanying Figures and/or described herein are merely exemplary and are not meant to limit the scope of the invention. It is to be appreciated that numerous variations of the invention have been contemplated as would be obvious to one of ordinary skill in the art with the benefit of this disclosure. Rather, the scope and breadth afforded this document should only be limited by the claims provided herein while applying either the plain meaning to each of the terms and phrases in the claims or the meaning clearly and unambiguously provided in this specification. TERMINOLOGY The terms and phrases as indicated in parenthesis (“ ”) in this section are intended to have the meaning ascribed to them in this section applied to them throughout this document including the claims unless clearly indicated otherwise in context. The term “or” as used in this specification and the appended claims is not meant to be exclusive rather the term is inclusive meaning “either or both”. References in the specification to “one embodiment”, “an embodiment”, “a preferred embodiment”, “an alternative embodiment”, “embodiments”, “variations”, “a variation” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment(s) or variation(s) is included in at least an embodiment or variation of the invention. The appearances of the phrase “in one embodiment” or “in one variation” in various places in the specification are not necessarily all referring to the same embodiment or variation. The term “couple”, “coupled”, “connected”, “joined”, “welded”, “glued”, “attached” or “fixed” as used in this specification and the appended claims refers to either an indirect or direct connection between the identified elements, components or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact. The phrases “upright-style bicycle” and “upright-style bicycle frame” and similar phrases refer to bicycles and frames respectively wherein the rider typically sits upright on a small seat/saddle typically leaning forwardly bracing his/her arm/hands against a pair of handlebars. The “upright-style bicycle” is the most common and well known type of bicycle and accordingly the phrase as used herein does not deviate from that commonly held meaning. In contrast, a “recumbent bicycle” or “recumbent tricycle” is one in which the rider leans generally rearwardly in a supine position and the seat typically includes a back rest for support. The term “road bike” refers to the style of bike that is most commonly used for riding on the road, street, or other paved, bitumen, or cement surfaces. This is opposed to the term “mountain bike” which refers to the style of bike that is most commonly used for riding where a “road bike” is not. The term “group” refers to a group of components commonly sold as a set or kit and used to complete the assembly of a bike on a particular bicycle frame of the rider's choice. A group typically includes a rear derailleur, a front derailleur, a set of front and rear brakes, brake levers and shifters, hubs and sometimes, a seat post and/or pedals. There are hundreds of tiny components associated with the cycling industry that are so common as to be redundant and therefore are excluded from the descriptions herein; Items such as wheel detail, tire detail, bearing detail, shifter detail, brake detail, sprocket detail, washers, nuts, bolts, bearings, O-rings, wheel hubs, spokes, cables and the like. Those individuals with ordinary skill in the art, with the benefit of this disclosure can, from the descriptions and diagrams provided herein easily and obviously understand and determine exactly what is required to manufacture, assemble, or buy items not shown. An Embodiment of a Unique Recumbent Bicycle with Improved Rear Wheel Attachment Method: An embodiment of a front wheel drive recumbent bicycle 1 is illustrated all or in part in FIGS. 1-22 . Referring primarily to FIG. 1 , in this embodiment, the bicycle is generally characterized by a relatively short wheelbase that is comparable to a traditional upright-style bicycle. The bicycle having a front end and a rear end. The front where the riders' feet 4 are depicted. The rear terminating behind and lower than the rider 60 . The front end also called ‘forward’ or ‘fore’, the rear end also call ‘rearward’ or ‘aft’. Again referring all or in part in FIG. 1 , starting at the rear of the bicycle and moving forward, the bicycle comprises a rear wheel support 48 , also referred to herein as a rear fork; a seat pan 47 and seat back 20 that are attached to the bicycle's main frame structure 45 with fixed or adjustable attachment at the seat pan mount 46 and seat back support 49 ; a front wheel support 44 , and an adjustable pedal location assembly 7 to accommodate riders of different sizes. The components of the bicycle including the wheel set comprised of front wheel 40 and rear wheel 42 , the drivetrain comprising front derailleur 5 , rear derailleur 10 , bottom bracket 6 , pedals 8 , cogs or freewheel 41 and chain 9 . The bicycle further comprising the handlebars 3 and the front brakes 43 and rear brakes 999 including brake/shift levers 2 . The drivetrain, handlebars and brake/shift levers are all typically interchangeable with those that are found in the bicycle industry such that specialized components are not required to outfit the recumbent bicycle of the present embodiment. The general position of a rider 60 when seated on the bicycle 1 is shown. Referring to FIG. 7 and FIG. 22 , a front wheel support 44 is shown, and is also known in the cycling industry as a “front fork” or “forks” or “fork”. The forks have a steerer tube 112 . The steerer tube 112 is commonly used by inserting it through a “head tube” 66 having bearings 110 , and the handlebars 3 clamp to the steerer tube 112 . By fastening the forks and handlebars together, when the handlebars are turned, they turn the front wheel in the direction desired. Again referring to FIG. 1 , both the front wheel support 44 and the rear wheel support 48 are common “front fork” styles used in the bicycle industry. In this embodiment, a “front fork”, depicted as the rear wheel support 48 , is uniquely utilized to attach the real wheel 42 to the rear end of the frame 45 using the rear head tube 61 . The rear fork 48 is rigidly clamped to the frame 45 and is not permitted to turn. No bearings are utilized for the rear fork 48 . Using a front fork to support a rear wheel embodies in FIG. 1 a unique recumbent bicycle with improved rear wheel attachment method. An Embodiment of a Unique Pedal Locating and Adjustment Method for Front Wheel Drive Recumbent Bicycles: Referring primarily to FIG. 2 , an embodiment in perspective view of an adjustable pedal locating assembly 7 as previously described in FIG. 1 is shown. The frame 45 supports the front wheel support 44 , also called a front fork, which supports the front wheel 40 . The steerer tube 112 (see FIG. 22 for detail) of the front fork 44 slips through the front head tube 66 , and protrudes through and beyond the front head tube 66 . The adjustable pedal location assembly support member 70 slips over the steerer tube of the front fork 44 and is clamped to the steerer tube 112 with the adjustable pedal locating assembly support member fasteners 65 . The handlebars 3 are similarly clamped to the steerer tube with handlebar fastener 64 as is common to the cycling industry. The front fork 44 , handlebars 3 , and adjustable pedal location assembly support member 70 are thus rigidly connected together and allowed to pivot in the head tube in unison in the same way a common bicycle handlebar turns the front wheel using bearings not shown. Refer to FIG. 7 for an exploded view with more detail. Slipping over the outside of the adjustable pedal locating assembly support member 70 is a bottom bracket support component 67 , to which the bottom bracket 6 is rigidly and permanently attached. The bottom bracket 6 is typical of components used in the cycling industry and houses bearings for the pedals, as are the front sprocket 63 , pedals 8 and pedal arms 69 . The chain 9 is also shown. A front derailleur support beam 71 extends from the bottom bracket 6 and is positioned such that a front derailleur may be attached to it in the common fashion that is used in the cycling industry by those with skill in the art. The front derailleur support beam 71 may also support lights or water bottles using mounting holes 72 . The Adjustable pedal location assembly support member 70 could be used to support lights, water bottles or other such attachments with mounting flange 83 . The sprocket 63 shown in this embodiment is a ‘single speed’. Mounting of a front derailleur is obvious to those with skills in the art using the front derailleur support beam 71 . An alignment screw 73 and alignment holes 74 are provided to optionally locate the pedals further in the fore or aft position and provide correct orientation for pedaling. Bottom bracket support component fasteners 75 are used to adjustably clamp the bottom bracket support component 67 to the pedal location assembly support member 70 . The uniquely combined sliding bottom bracket support component 67 and adjustable pedal location assembly support member 70 embody in FIG. 2 a unique pedal locating and adjustment method for front wheel drive recumbent human powered vehicles. Pedal Assembly and Chain Tensioner Embodiment: Referring primarily to FIG. 3 , a depiction of a pedal assembly is shown in side view 62 . The alignment screw 73 is shown in exploded view. On the bottom side of the pedal assembly is a tubular appendage 76 which is attached to the bottom bracket support component 67 . The tubular appendage 76 supports a chain tensioner assembly 78 . In this embodiment, the chain tensioner assembly 78 is comprised of an idler arm 80 , an idler wheel 79 , a spring 82 , a spring pivot on the support bracket 77 , a spring attachment on the idler arm 81 and a pivot point 84 . In this embodiment the chain tensioner is depicted as providing tension to the chain 9 on the side of the front sprocket 63 which experiences highest tension during the pedaling process. The embodiment depicted is only meant to convey the utility of a chain tensioner, the technology for which is common in the industry. As force increases or decreases in the chain 9 , the idler arm 80 is allowed to pivot about pivot point 84 with spring 82 keeping tension on the chain 9 . When a shock absorbing front shock is installed, the distance between the front wheel center and the front sprocket 63 centers will fluctuate either during a bump, or rebound. The purpose of the chain tensioner is to keep the chain 9 tight on the front sprocket 63 as the distance between the centers just described fluctuates. The embodiment depicted is only meant to convey the utility of a chain tensioner, the technology for which is common in the industry. A chain tensioner could also be mounted on the wheel near the rear derailleur. Pedal Assembly Adjustment Embodiment: Referring primarily to FIG. 4 , a depiction of the pedal assembly 7 is shown. The pedal assembly 7 is comprised of the bottom bracket support component 67 of this embodiment, the bottom bracket 6 , and all previously described attachments including the bottom bracket support component fasteners 75 . The bottom bracket support component 67 and the bottom bracket 6 are permanently joined and in this embodiment are supported by gussets 86 . The pedal assembly 7 of this embodiment is longitudinally adjustable on the adjustable pedal location assembly support member 70 . Pedal assembly 7 adjustment is accomplished by loosening the bottom bracket support component fasteners 75 and alignment screw 73 , and sliding the entire assembly fore or aft relative to pedal location assembly support member 70 . The Adjustable pedal location assembly support member 70 has alignment holes 74 at regular intervals axially located on the adjustable pedal location assembly support member 70 , which the pedal assembly alignment hole 85 aligns with, and the alignment screw 73 is inserted through both to provide vertical alignment. After the desired position is attained and the alignment screw 73 is inserted, the crank set support component fasteners 75 are re-tightened and this provides a clamping force upon the adjustable pedal location assembly support member 70 to rigidly locate the pedal assembly 7 upon the adjustable pedal location assembly support member 70 . This is merely an embodiment of one fastening method. Other methods are common to those with skill in the art. Alternative Pedal Beam Embodiment: Referring primarily to FIG. 23 an alternative embodiment of the adjustable pedal location assembly support member 70 is shown having a support truss 156 . The adjustable pedal location assembly support member 70 and support truss 156 are integral and joined together as one unit. Assembly of this unit would require that it be placed adjacent to the head tube 66 and the front fork 44 steerer tube is then inserted. Fasteners 155 and 157 fasten the adjustable pedal location assembly support member 70 and support truss 156 to the steerer tube, and then the handlebar is attached as normal. Pivotable Pedal Support Beam Embodiment: Referring primarily to FIG. 13 , an alternative configuration of the adjustable pedal locating assembly support member is shown in side view 145 and perspective view 141 . In this embodiment, the adjustable pedal locating assembly support member 143 is permitted to pivot about a base 142 in a turret like fashion. The base 142 is allowed to pivot around a base mount member 144 which can be adjustably fastened to the front fork steerer tube with a clamping piece and fasteners 145 . The assembly 141 is attached to a front wheel drive recumbent vehicle. Alternatively, for a rear wheel drive recumbent, base mount 144 would be permanently attached to the frame and not able to pivot with the wheel. Yet in both variations the adjustable pedal locating assembly support member 143 is permitted to pivot about a base 142 in a turret like fashion. When the desired location has been achieved, the fasteners 146 are tightened, preventing relative motion. The purpose and effect of the pivotable support member is to raise or lower the position of the pedals relative to the rider seat pan height 148 as shown with arrow 147 . Pedal height adjustment of this kind is advantageous for individual riders to be able to local the height of the pedals in the location preferred for their unique physiology providing optimal comfort. Chain Tensioner: Referring primarily to FIG. 12 , a depiction of another embodiment of a chain tensioner is shown in view 131 . In view 131 is shown the frame 45 , front forks 44 embodied as shock absorbing design, handlebars 3 , embodiment of an adjustable pedal locating assembly support member 70 , adjustable pedal locating assembly 7 and a chain tensioner 78 . When a shock absorbing front shock 44 is installed, the distance between the front wheel center 136 and the sprocket center 133 will fluctuate either during a bump, or rebound of the shock. The purpose of the chain tensioner 78 is to keep the chain 9 tight on the sprocket 63 as the distance between the centers just described fluctuates. The embodiment depicted is only meant to convey the utility of a chain tensioner, the technology for which is common in the industry. A chain tensioner could also be mounted on the wheel near the rear derailleur on the opposite side of the wheel sprocket at location indicated by 135 . It may also be desirable to have a chain tensioner on the high tension side of the sprocket 63 as shown or the low tension side of the sprocket at the location indicated by leader arrow 134 or some permutation thereof. An Embodiment of a Uniquely Combined Handlebar and Pedal Locating Method for a Front Wheel Drive Recumbent Bicycles: Referring primarily to FIG. 5 , several perspective views are shown. In view 87 , pedal assembly 88 is embodied with an alternative location method. View 87 shows pedal assembly 88 , consisting of a bottom bracket 6 , pedals 8 , and other common components known to those with skill in the art. The bottom bracket 6 is permanently attached to a support piece 89 and is retained and located using threaded embossments 90 permanently affixed to the adjustable pedal locating assembly support member 70 and regularly spaced. This embodiment would achieve similar results as the other embodiments described herein. In view 97 , pedal assembly 95 is embodied with an alternative locating method. View 97 shows pedal assembly 95 as being retained and located using an oblong rod 98 and pin 99 with the rod being rigidly affixed to the pedal assembly 95 , inserted through holes in the adjustable pedal locating assembly support member 70 and regularly spaced. This embodiment would achieve similar results as the other embodiments described herein. In view 92 , pedal assembly 96 is embodied with an alternative locating method. View 92 shows pedal assembly 96 as being retained on the end of the adjustable pedal location assembly support member 70 and sliding through a handlebar mounted adjustment and support tube 94 . The adjustable pedal locating assembly support member 70 is retained with any number of fasteners 93 . The handlebar mounted adjustment and support tube 94 is rigidly attached to the handlebars 91 forming an integral member. The handlebar unit 91 is then clamped to the front fork 44 steerer tube as shown in other embodiments depicted herein. 40 is the front wheel. A chain 9 is also shown. This embodiment would achieve similar results as the other embodiments described herein but is different in that the adjustable pedal locating assembly support member 70 slides through the handlebar piece. The uniquely combined adjustable pedal locating assembly support member 70 and integral handlebar support tube 94 embody in FIG. 5 a uniquely combined handlebar and pedal locating method for a front wheel drive recumbent bicycles. Range of Pedal Adjustment Over Prior Art Details: Referring primarily to FIG. 20 , a depiction of the prior art is compared to that of the pedal adjustment revealed herein. Shown in view 149 is the prior art with a clamping area 150 and adjustment length 151 . Shown in view 152 is the revealed art with a clamping area 154 and adjustment length 153 . It is shown that for a comparable clamping length where 150 and 154 are equal to one another, an improved adjustment length is realized in the revealed art. It is evident that prior art adjustment length 151 is of a reduced length than that of the revealed art adjustment length 153 even though approximately the same amount of material is used for the support beam. This diagram illustrates one of the advantages of the revealed art over prior art. By using less material, weight is saved on the vehicle—which is greatly advantageous on human powered vehicles. Rear Wheel Support Angle Adjustment Details: Referring primarily to FIG. 6 , a depiction of the rear wheel attachment method as previously described in FIG. 1 is shown in view 100 in perspective. The rear wheel 42 , is attached to a rear wheel support 48 (also known as a fork). The rear wheel support 48 is a “front fork” commonly used in the bicycle industry for attaching a bicycle's front wheel, but in the revealed art it is used to attach the rear wheel instead. The rear wheel 42 is retained with a hub bolt 106 common to the industry. The rear wheel support 48 is inserted into and retained to the frame 45 with a rear head tube 61 that is permanently attached to the frame 45 . No bearings are used and the inner diameter of the rear head tube 61 is such that when clamped to the fork, clamping force rigidly retains the fork in the desired location. This clamping method is obvious to those with skill in the art and could be achieved in many other ways. In this embodiment, the rear head tube 61 is permanently affixed to frame 45 by using methods known to those with skill in the art (such as welding). In this embodiment, clamping force is accomplished with a top fastener 104 and bottom fastener 105 which provide clamping force upon the steerer tube of the rear wheel support 48 (also known as a fork). Utilizing a “front fork” to attach a rear wheel is unique and advantageous to the cycling industry for several reasons. One, the rear wheel support 48 can be exchanged by the owner to any brand or style they choose providing a high level of choice for the owner. A few examples are Aluminum forks, Steel forks, Carbon Fiber forks, or shock absorbing forks. Each fork style has performance characteristics that cyclists find beneficial under varying riding conditions (such as racing or touring, on or off road). Two, the rear wheel support 48 can be a “shock absorbing” fork. This is highly advantageous in that it significantly reduces the complexity over prior art in accomplishing a “full suspension” recumbent bicycle when used in conjunction with a shock absorbing fork on the front wheel. It also significantly reduces complexity over prior art when using a rear shock absorbing fork instead of complicated pivoting mechanism of prior art. Third, the frame geometry and ride height of the rider can be adjusted by adjusting the clamping location of the rear head tube 61 on the rear wheel support 48 . Adjusting the ride height up or down by adjusting the clamping position upon the steerer tube of the rear fork. This simple adjustment method is comparable to how seat posts are adjusted in prior art. The rear wheel support 48 is a ‘front fork’ commonly used in the industry to support the front wheel of a bicycle, but in the revealed art, a front fork is used instead to support the rear wheel. The utility of this embodiment is very advantageous because a rider may, when riding their bike on hard paved surfaces that are smooth, want to use rigid forks in both the front and rear positions because there are pedaling energy efficiencies gained. It is common knowledge to those in the cycling sport that shock absorbing suspensions consume energy when pedaling. This is minimized with rigid frame and wheel support construction. Alternatively, the rider may want to ride their bike on bumpy dirt roads, in which case, with the revealed art, the rider may, at their discretion, swap the rigid forks in both the front and the rear and use instead shock absorbing forks in both the front and rear, and thus transform their “rigid frame” human powered vehicle into a “fully-suspended” human powered vehicle at their leisure. Using the shock absorbing forks will drastically increasing the riders comfort when riding on bumpy roads or tracks and provides highly advantageous options for the rider when configuring their bicycle. Alternatively, the rider may choose to have a shock absorbing fork in the front and rigid in the rear or some combination thereof based upon their own belief of the “best” combination. Cyclists will find this ability highly advantageous. Touring cyclists who ride for extended durations upon their bikes, perhaps for months, over unanticipated and unpredictable terrain will find this ability especially desirable. Carrying a spare fork for alternating conditions and being able to swap it out with the other would be highly advantageous and desirable. Referring primarily to FIG. 6 , a depiction of the rear wheel attachment method as previously described in FIG. 1 is shown in view 101 in profile. In this embodiment the rear wheel support 48 is perpendicular to the frame 45 . Depending upon the desired performance characteristics, the angle of the rear wheel support 48 may be adjusted by varying the attachment angle of the rear head tube 61 creating an angle that is not perpendicular to the main frame 45 , but is instead leaning in the direction of angle 102 or angle 103 . In this embodiment, the rear head tube 61 angles 102 and 103 are not intended to be manually adjusted, and the attachment is depicted as permanent as would be built by the frame manufacturer. One can easily envision that in other embodiments, the head tube 61 could be made to be adjustable rather than fixed to the frame 45 . This would be trivial to those with skill in the art and may be beneficial for certain types of cycling or frame loading situations or sports such as ‘touring’ or ‘racing’ either ‘on’ or ‘off’ road. Exploded View of Rear Wheel Support Frame: Referring primarily to FIG. 7 , an exploded view 107 of the frame 45 is shown. Frame 45 has a front end 111 and a rear end 108 . A partial view of the seat pan 47 is shown with attachment embossments 46 . The Adjustable pedal locating assembly support member 70 is shown. The handlebars 3 are shown. The front fork 44 is shown. The front fork steerer tube 112 is shown. Also shown is a rear fork 48 which does not have shock absorbers, and for reference a rear fork which has shock absorbers 109 . The rear forks can be used interchangeably, as can the front forks, which must be wider at the axle mounts to allow for the wider wheel hub having sprockets attached (not depicted). Various Frame Embodiments: Referring primarily to FIG. 8 , several views of various frame embodiments are shown. The purpose of the views of FIG. 8 are to convey the idea that the frame has been embodied as generally straight and tubular, but in fact could be many shapes or profiles. In view 113 is shown the embodiment of the frame 45 as primarily discussed in the bulk of this document. Frame 45 is essentially a straight tube having a front and rear with a front head tube 66 and a rear head tube 61 . A seat 114 is shown. In view 115 is shown the embodiment of a frame 116 . Frame 116 is a bent tube having a front and rear with a front head tube 66 and a rear head tube 61 . A seat 114 is shown. In view 117 is shown the embodiment of a frame 118 . Frame 116 has a tubular front end, and a tubular rear end, connected by a generally flat section of material. Frame 116 still has a front head tube 66 and a rear head tube 61 in the same locations. A seat 114 is shown. Pannier Embodiments: Referring primarily to FIG. 9 , in view 119 and perspective view 998 a recumbent bicycle of FIG. 1 is shown with panniers 120 attached. The panniers 120 are attached to frame 45 at the rear end of the bike, which in this embodiment has a rearward protrusion 121 , with an attachment screw 122 . Attachment screw 122 can be removed, thereby releasing the pannier support member 123 and the panniers 120 . Referring primarily to FIG. 10 , in view 124 is shown the rear end of frame 45 , rearward protrusion 121 , and the pannier attachment 123 . The pannier attachment 123 is embodied as a tube which slides over the rearward protrusion 121 . In view 125 is shown a perspective of the rear end of frame 45 with the pannier attachment 123 detached. The pannier attachment screw 122 is shown detached also. The pannier attachment 123 is embodied as a tube which slides over the rearward protrusion 121 and retained with attachment screw 122 . The panniers 120 , attach to the pannier attachment 123 . An Embodiment of a Unique Recumbent Bicycle Having an Improved Pedal Locating and Adjustment Method for Rear Wheel Drive Recumbent Bicycles; and, an Embodiment of a Unique Combination of Said Improved Pedal and Adjustment Method as Well as Improved Rear Wheel Attachment Method: Referring primarily to FIG. 11 , in view 126 is shown the bicycle generally embodied in FIG. 1 except in this embodiment, the bicycle is embodied as a rear wheel powered bicycle having a fairing 127 with a front attachment 128 and a rear attachment 129 . Fairings are typically translucent or clear and provide for improved aerodynamic characteristics compared with the unfaired variation and may also provide protection from the wind and rain. In this embodiment, the concept is almost identical to the front wheel driven bicycle of FIG. 1 . However, the frame 45 extends beyond the front head tube 66 and forms a protruding extension 130 to which the sliding bottom bracket support component 67 is attached in the same manner described in FIG. 2 . The extension is part of the frame and does not pivot. This is necessary for the rear wheel drive configuration. The front wheel and handle bars turn in common fashion to that of existing art. The uniquely combined sliding bottom bracket support component 67 and protruding extension 130 embody in FIG. 11 a unique recumbent bicycle having an improved pedal locating and adjustment method for rear wheel drive recumbent bicycles. FIG. 11 also embodies a unique combination of said improved pedal and adjustment method as well as improved rear wheel attachment method. Underframe Steering Embodiment: Referring primarily to FIG. 14 , a perspective view of the recumbent bicycle in FIG. 1 with an alternative ‘under frame’ handlebar embodiment shown. In similar fashion to that previously described the front forks 44 support underframe handlebars 139 and the adjustable pedal locating assembly 7 . The front forks 44 are supported by and attached to the frame 45 in similar fashion as is common in the bicycle industry. In this embodiment, the underframe handlebars 139 are located adjacent to the front header tube 66 , but on the bottom side of the front header tube 138 instead of the top side of the front header tube 137 . It is an intuitively obvious progression of thought that the adjustable pedal locating assembly 7 and the underframe handlebars 139 could be swapped in their positions and attached to the front forks 44 . In an alternative embodiment not shown, the front forks 44 could have the handlebars advantageously welded or permanently attached to them, further simplifying the assembly and reducing weight. Referring primarily to FIG. 15 , a perspective view of the recumbent bicycle in FIG. 1 with an alternative ‘under frame’ handlebar embodiment is shown. In similar fashion to that previously described the front forks 44 support underframe handlebars 139 and the adjustable pedal locating assembly 7 . The front forks 44 are supported by and attached to the frame 45 using the front header tube 66 in similar fashion as is common in the bicycle industry and described previously herein. The seat 47 is also shown. In this embodiment, the underframe handlebars 139 are located adjacent to the front header tube 66 , but on the bottom side of the front header tube 138 instead of the top side of the front header tube 137 . It is an intuitively obvious progression of thought that the adjustable pedal locating assembly 7 and the underframe handlebars 139 could be swapped in their positions and attached to the front forks 44 . In an alternative embodiment not shown, the front forks 44 could have the handlebars advantageously welded or permanently attached to the front forks 44 to further simplify the assembly and reduce weight. Tandem Embodiments: Referring primarily to FIG. 16 , a profile view of an alternative embodiment of the recumbent bicycle in FIG. 1 having an alternative ‘tandem rider’ embodiment for 2 riders at the same time with both riders facing forward. A front wheel 40 and a rear wheel 42 are shown. Attached to and extending from the frame 45 rearward protrusion 121 in similar fashion to that shown for the pannier attachment described in FIG. 10 , is a tandem seat attachment 317 . The tandem seat attachment 317 is comprised of a tubular member to which is attached a rear seat 316 that is facing forward in the same direction of the front seat 47 . In front of the rear seat 316 is embodied a tandem adjustable pedal locating assembly 315 . The tandem adjustable pedal locating assembly 140 position is adjustable along the axis of the frame 45 . The rear seat 316 could also be permanently attached to frame 45 by extending frame 45 beyond that which is depicted to support the rear seat 316 . Advantageously, the front fork assembly including wheel, sprocket and all other drivetrain components—except perhaps the chain—could be duplicated entirely and used in the rear as well. Referring primarily to FIG. 17 , a profile view of an alternative embodiment of the recumbent bicycle in FIG. 1 having an alternative ‘tandem rider’ embodiment for two riders at the same time with one rider facing forward and one rider facing aft in the opposite direction. A front wheel 40 and a rear wheel 42 are shown. Attached to and extending from the frame 45 , a rearward protrusion 121 is shown in similar fashion to that shown for the pannier attachment described in FIG. 10 . An adjustable pedal locating assembly 7 which has been slid over and clamped to attachment member 319 . The pedal assembly 7 attachment member 319 is comprised of a tubular member supporting the pedal assembly 7 . Attachment member 319 is rigidly attached to frame 45 . The pedal assembly 7 position is adjustable along the axis of the attachment member 319 . A front seat 47 is facing forward, and a rear seat 318 is facing in the opposite direction. Two riders can ride this tandem recumbent bicycle and would face in the opposite direction to one another. The pedal assembly 7 attachment member 319 shown could also be permanently attached to frame 45 by extending the rearward protrusion 121 beyond that which is depicted and eliminating detachable member 319 . Advantageously, the front fork assembly including wheel, sprocket and all other drivetrain components—except perhaps the chain—could be duplicated entirely and used in the rear. Referring primarily to FIG. 18 , a perspective view is shown of an adjustable pedal assembly used for the tandem rider embodiments shown in FIG. 16 and FIG. 17 . The frame 45 supports the pedal assembly bottom half 323 and pedal assembly top half 321 . The top half 321 and bottom half 323 are clamped together around the frame 45 and held in place frictionally by clamping force provided by bolts 322 . To the top half 321 is rigidly attached the bottom bracket 6 support member 320 . The remainder of the assembly is similar to that depicted in FIG. 2 . By loosening bolts 322 , the pedal assembly may slide forward or aft on the frame 45 to adjust the location of the assembly relative to the rider. Referring primarily to FIG. 19 , an exploded perspective view of the adjustable pedal assembly of FIG. 18 is shown. The embodiment shown depicts in exploded view the pedal assembly bottom half 323 , pedal assembly top half 321 , and bolts 322 . In this embodiment, the bolt holes 324 are threaded. This simplicity and multi-use of components across three frame embodiments (the single rider, tandem riders both forward facing, and tandem riders one facing forward the other aft), is cause for efficiency in maintainability and cost reduction during manufacture. For example, during manufacture, additional frame members and assembly jigs are not required for all three modes of construction. Tricycle Embodiment: Referring primarily to FIG. 21 , a tricycle embodiment is shown wherein each of the three wheels is supported using the front fork 44 of a bicycle. In this embodiment, each fork—normally only used on the front wheel of a bicycle, could be interchanged with a shock absorbing design. The ability to swap forks and interchange them at the will of the owner is highly advantageous. Also shown in this embodiment is the pedal adjustment method shown in FIG. 11 . FIG. 21 embodies a unique recumbent tricycle having an improved pedal locating and adjustment method. FIG. 21 also embodies a unique recumbent tricycle with improved rear wheel attachment method.
A recumbent bicycle or recumbent tricycle with a removable rear fork that can be swapped with another rear style fork. The rear fork is clamped so that is cannot turn but can be easily swapped. The rear fork can be swapped according to riding conditions or for aesthetics. The rider may use one fork for stiff characteristics, another shock absorbing fork for off-road, or for any style or color at the discretion of the rider, thus allowing greater flexibility. Also, the bicycle includes removable tandem seat for a second rider with a removable pedal assembly for the second rider. In this way the same bicycle can be single or tandem capable. Another feature is a removable pannier rack assembly which adds more choices and capabilities for the rider. These various combinations are highly appealing to the cyclist community.
1
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional of U.S. application Ser. No.10/750,083, filed Dec. 31, 2003, which claims benefit to U.S. Provisional Application Ser. No. 60/438,016, filed on Jan. 3, 2003, and U.S. Provisional Application Ser. No. 60/486,275, filed on Jul. 10, 2003, all of which are hereby incorporated by reference herein. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not applicable. BACKGROUND OF THE INVENTION [0003] Many plants and plant parts are of great economic importance to people. Fruit, vegetable, edible tuber and cut flower businesses are all multibillion dollar industries globally. Turf grass is another multibillion dollar industry. Over the years, people have learned to increase the production of various economically important plants and plant parts. Chemical agents have been applied to plants to increase the marketable yield of fruits, for example, by inhibiting fruit drop from the trees. In addition, people have learned to reduce the loss of economically important plant parts during the post-harvest storage and marketing period. In this regard, various chemical agents have been used to prolong the storage and shelf life of fruits, vegetables and cut flowers. However, many of the yield-increasing agents have the undesirable effect of causing the fruits and vegetables to soften and thus lead to poor storage and shelf life. Furthermore, many of the yield-increasing and the storage and shelf life-prolonging agents have toxicological and environmental concerns. There is a tremendous interest in the plant industry to find alternative agents. [0004] Another major challenge to the plant industry relates to the protection of economically important plants from abiotic and biotic stress-related injuries. Specifically, over 60% of the crop loss in the U.S. from the late 1940s to the late 1990s was due to abiotic stresses (see USDA Agricultural Statistics, 1998). Abiotic stresses include chilling, freezing, drought, heat and other environmental factors. Biotic stresses, which include those caused by insects, nematodes, snails, mites, weeds, pathogens (e.g., fungus, bacteria and viruses), and physical damage caused by human and non-human animals, have also led to significant crop loss in the U.S. Thus, there is a tremendous interest in the plant industry to find a technology that can be used to prevent or mitigate stress injury and to accelerate recovery following a stress injury. [0005] In the recent years, certain phospholipids such as lysophosphatidylethanolamine (LPE) have been found to be able to deliver some beneficial effects to various economically important plants and plant parts, which include protecting the plants from stress-related injuries (see WO 01/721330; and plant parts (see Farag, K. M. et al., Physiol. Plant, 87:515-524 (1993); Farag, K. M. et al., HortTech., 3:62-65 (1993); Kaur, N., et al., HortScience, 32:888-890 (1997); Ryu, S. B., et al., Proc. Natl. Acad. Sci. U.S.A., 94:12717-12721(1997); U.S. Pat. Nos. 5,126,155 and 5,110,341; and WO 99/23889). However, for large scale applications, these lysophospholipids are currently relatively expensive. Alternative agents that have the potential to provide cost effective delivery of the same or greater effects produced by the lysophospholipids are desired in the art. SUMMARY OF THE INVENTION [0006] The present invention provides methods for delivering various beneficial effects to a plant or plant part by treating the plant or plant part with an effective amount of modified lecithin to change the health, growth or life cycle of the plant or plant part. [0007] In one aspect, the present invention relates to a method for improving the quality of a plant part (e.g., the quality of fruits, vegetables, flowers or tubers) by treating the plant part or its corresponding plant with an effective amount of modified lecithin. As an example, the method can be used to improve the turgidity, color and flavor of fruits and vegetables and to reduce fruit cracking. Modified lecithin that can be employed in the methods of the present invention include enzyme-modified lecithin (EML) and chemically modified lecithin such as acetylated lecithin (ACL) and hydroxylated lecithin (HDL). [0008] In another aspect, the present invention relates to a method of retarding senescence in a plant part by treating the plant part or its corresponding plant with an effective amount of modified lecithin. The retardation of senescence can lead to prolonged storage and shelf life for a variety of products such as fruits, vegetables, flowers and tubers. [0009] In another aspect, the present invention relates to a method for increasing the size, weight or both of a plant part (e.g., fruits) by treating the plant part or its corresponding plant with an effective amount of modified lecithin. [0010] In another aspect, the present invention relates to a method for stimulating the growth of a plant or plant part by treating the plant or plant part with an effective amount of modified lecithin. This method can be used to enhance root formation and development of roots on cuttings, to enhance tuber formation, and to stimulate turf grass growth. [0011] In another aspect, the present invention relates to a method of improving the aesthetic attributes of a plant or plant part by treating the plant or plant part with an effective amount of modified lecithin. A plant or plant part with improved aesthetic attributes will look more appealing to an ordinary consumer. [0012] In another aspect, the present invention relates to a method for increasing fruit set on a plant or reducing fruit drop by treating the plant or a suitable part thereof with an effective amount of modified lecithin. [0013] In another aspect, the present invention relates to a method of protecting a plant or plant part from a stress-related injury by treating the plant or plant part with an effective amount of modified lecithin. [0014] In other aspects, the present invention relates to methods of eliciting the hypersensitive response in a plant or plant part, which can be detected by measuring the increase in the total activity of one or more enzymes such as phenylalanine ammonia lyase (PAL), polyphenol oxidase (PPO), peroxidase (POD) and indole-3-acetic acid oxidase (IAA oxidase) in a plant or plant part, and increasing lignin synthesis in a plant or plant part by treating the plant or plant part with an effective amount of modified lecithin. [0015] In another aspect, the present invention relates to a method for protecting a plant or plant part from a stress-related injury caused by an abiotic or biotic stress. The method involves adding an effective amount of modified lecithin into the agrochemical intended to be applied to the plant or plant part. BRIEF DESCRIPTION OF THE DRAWINGS [0016] FIG. 1 shows changes in protein content and PAL activity in radish cotyledons exposed to 1-amminocyclopropane-1-carboxylic acid (ACC, a precursor to ethylene), kinetin, and EML all at 20 mg/L. [0017] FIG. 2 shows short-term kinetics of PAL activity in EML-treated radish cotyledons. [0018] FIG. 3 shows effect of EML on lignin content of kinetin-induced expanding cotyledons of radish. [0019] FIG. 4 shows changes in POD activity in cotyledons of radish exposed to ACC, kinetin, or EML. [0020] FIG. 5 shows PAL activity in leaves of mung bean seedlings treated with or without EML (both 20 mg/L) via the transpiration stream. [0021] FIG. 6 shows the effect of LPE and EML on PPO activity in radish cotyledons. [0022] FIG. 7 shows the effect of LPE and EML on IAA oxidase activity in radish cotyledons. [0023] FIG. 8 shows the effect of lecithins on the activity of IAA oxidase in expanding radish cotyledons. [0024] FIG. 9 shows the impact of soy EML on grape firmness. [0025] FIG. 10 shows the impact of soy EML on apple firmness. [0026] FIG. 11 is a product-limit survival fit survival plot, which illustrates the ability of 1000 ppm soy EML aqueous solution to improve vine-ripe tomato fruit storage when applied pre-harvest. [0027] FIGS. 12-14 illustrate the sizing impact of soy EML applied approximately 2 weeks prior to harvest in Fowler, Calif. on Summer Sweet peaches. [0028] FIGS. 15 and 16 illustrate the color impact of soy EML applied approximately 2 weeks prior to harvest in Fowler, Calif. on Summer Sweet peaches. [0029] FIGS. 17-19 illustrate the sizing impact of soy EML, applied approximately 10% color break in Mendota, Calif. on red bell peppers. [0030] FIGS. 20 and 21 illustrate the sizing impact of soy EML applied approximately 3 weeks prior to harvest on McIntosh apples in Gays Mills, Wis. [0031] FIGS. 22-24 illustrate the root formation impact of 20 ppm soy EML solution on mung bean rooting. FIGS. 22 and 23 are pictures of control and EML-treated roots at the end of the experiment. FIG. 24 shows the average number of roots in the control and EML-treated group at the end of the experiment. [0032] FIG. 25 illustrates the impact of soy EML on fruit drop of McIntosh apples conducted in Gays Mills, Wis. DETAILED DESCRIPTION OF THE INVENTION [0033] It is disclosed here that modified lecithin, including the relative low cost EML, ACL and HDL, can deliver a variety of beneficial effects when applied to a plant or plant part by changing the health, growth or life cycle of the plant or plant part. The term “life cycle” is used broadly here to encompass both the pre-harvest and post-harvest stages of the plant or plant part. In general, modified lecithin can improve the quality and overall health, stimulate the growth and retard the senescence process in a plant or plant part. The modified lecithin can also increase fruit set, reduce fruit drop and protect a plant or plant part from stress-related injuries. Based on these properties, modified lecithin can be applied in many different ways to benefit the plant industry. For example, modified lecithin can be applied to improve the quality of fruits, vegetables, tubers and cut flowers in terms of their turgidity, color, flavor and scent, and to reduce fruit cracking. Modified lecithin can also be applied to prolong the storage and shelf life of various plant parts such as fruits, vegetables, tubers and cut flowers through retarding or delaying the senescence process in these plant parts. By taking advantage of the growth stimulation activity of modified lecithin, one can increase the size and/or weight of fruits, vegetables and tubers, stimulate turf grass growth, and increase the number of tubers, roots and shoots. One can also make a plant or plant part more appealing to consumers by using modified lecithin to improve the overall health of the plant or plant part. Furthermore, modified lecithin can be applied to increase fruit production by increasing fruit set and reducing fruit drop. In addition, modified lecithin can be used to reduce crop loss caused by stress-related injuries. The beneficial effects disclosed here are applicable to all plants and plant parts that have commercial value (e.g., fruits, flowers, leaves, roots and stems). Preferably, the present invention is practiced on fruits, vegetables, tubers, cut flowers, and their corresponding plants. The present invention is also preferably practiced on turf grass, bedding plants and other functional and decorative plants. [0034] At the physiological level, inventors discovered that EML can trigger a cascade of hypersensitive reactions in a plant that are characterized by the induction of a variety of enzymes, such as lignin synthesizing enzymes including PAL, POD and PPO, leading to the synthesis and deposition of additional lignin to the plant cell walls (see examples below). This response is similar to the self-defense hypersensitive response seen in plants that have been infected by pathogens (e.g., fungi, bacteria or viruses), which secrete one or more elicitors that induce the response. Through the induction of PAL, POD, PPO and other enzymes, the elicitor-induced hypersensitive response is known to impact the direction of carbon flux (e.g., to increase phenylpropanoid, isoprenoid and phytoalexin production) which in turn causes various physiological response such as growth of vegetative and reproductive organs, color development and stress mitigation (Hammond-Kosack K., and Jones J 2000 Responses to Plant Pathogens, In: Biochemistry & Molecular Biology of Plants, Buchanan B B, Gruissem W, and Jones R L eds. American Society of Plant Biologists, Rockville, Md.). One of the end results that relates to stress mitigation is the collapse of the infected plant tissue, which traps and thus prevents the pathogens from infecting other parts of the plant. Without intending to be limited by theory, the inventors believe that the hypersensitive response triggered by EML, which occurs in the absence of a physical wound, is not as dramatic as that triggered by an elicitor from a pathogen and thus does not lead to tissue collapse nor does it impede normal tissue function. However, the limited additional amount of lignin deposited to the cell walls is sufficient to reinforce the cell walls and provide additional structural integrity to plant tissues. As a result, the plant or plant part can better retain water, nutrients and other essential components, leading to better overall quality and health. For harvested plant parts such as fruits, vegetables, tubers and cut flowers, this will also lead to the retardation or delay of the senescence process and thus prolong their storage and shelf life. For living plants and plant parts, this can translate into better growing capabilities, which for example can lead to bigger and heavier products. Furthermore, the improved structural integrity and ability to retain important components can lead to increased fruit set and a reduction in fruit drop. In addition, the plant or plant part can better withstand various stress situations. [0035] As used herein, the term “modified lecithin” means a lecithin modified to enrich its constituency of plant growth modifying compounds, specifically including EML, ACL, HDL and other similar modified lecithins that have plant growth beneficial effects disclosed here for the specific modified lecithins EML, ACL, and HDL. Using the effects noted for EML, ACL and HDL as examples below, one of ordinary skill in the art can test other modified lecithins for the beneficial effects disclosed here and demonstrated in the examples below using the techniques described here. To the extent that the exact efficacy of a particular modified lecithin is not demonstrated in the examples below, it can be easily determined by a skilled artisan through routine experimentation with the systems described in the examples or other systems that a skilled artisan is familiar with. For example, a skilled artisan can use the radish cotyledon system described in Example 1 to measure either lignin deposition or at least one of the PAL, POD, PPO and IAA oxidase enzymatic activities. If a modified lecithin increases lignin deposition or the enzymatic activities measured, the modified lecithin is within the scope of the present invention. [0036] Commercially, lecithin refers to a complex product derived from animal or plant tissues that is commonly used as a wetting and emulsifying agent in a variety of commercial products and is not normally expected to have biological effects in plants. Lecithin contains acetone-insoluble phospholipids (including phosphatidylcholine (PC), phosphatidylethanolamine (PE), phosphatidylinositol (PI), phosphatidic acid (PA), phosphatidylglycerol (PG), phosphatidylserine (PS) and other phospholipids), sugars, glycolipids, and some other substances such as triglycerides, fatty acids, and cholesterol. Refined grades of lecithin may contain any of these components in varying proportions and combinations depending on the type of fractionation used. In its oil-free form, the preponderance of triglycerides and fatty acids is removed and the product contains 90% or more phosphatides representing all or certain fractions of the total phosphatide complex. The consistency of both natural grades and refined grades of lecithin may vary from plastic to fluid, depending upon free fatty acid and oil content, and upon the presence of absence of other diluents. Its color varies from light yellow to brown, depending on the source and on whether it is bleached or not (usually by hydrogen peroxide and benzoyl peroxide). Lecithin is only partially soluble in water, but it readily hydrates to form emulsions. The oil-free phosphatides are soluble in fatty acids, but are practically insoluble in fixed oils. When all phosphatide fractions are present, lecithin is partially soluble in alcohol and practically insoluble in acetone. In a preferred embodiment of the present invention, a food-grade lecithin is used as the starting material to make modified lecithin. This will minimize the safety and environmental concerns over applying modified lecithin to food products. However, a non-food-grade lecithin can also be employed. By current definition, a food-grade lecithin (CAS: 8002-43-5) has the following properties: (1) acetone-insoluble matter (phosphatides) is not less than 50%; (2) acid value is not more than 36; (3) heavy metals (as Pb) is not more than 0.002%; (4) hexane-insoluble matter is not more than 0.3%; (5) lead is not more than 10 mg/kg; (6) peroxide value is not more than 100; and (7) water is not more than 1.5%. [0037] EML refers to a lecithin that has been enzymatically modified (e.g., by phospholipase A 2 or pancreatine), a modification done to enhance the surfactant or emulsifying characteristics of the lecithin. Chemical procedures can also be used to make similar modifications as those made by phospholipase A 2 . In a preferred embodiment, a food-grade EML is used in the present invention to minimize the safety and environmental concerns. However, non-food-grade EML can also be employed. By current definition, a food-grade EML has the following properties: (1) acetone-insoluble matter (phosphatides) is not less than 50%; (2) acid value is not more than 40%; (3) lead is not more than 1 ppm as determined by atomic absorption spectroscopy; (4) heavy metals (as Pb) is not more than 20 ppm; (5) hexane-insoluble matter is not more than 0.3%; (6) peroxide value is not more than 20; (7) water is not more than 4%; and (8) lysolecithin is 50 to 80 mole percent of phosphatides as determined by “Determination of Lysolecithin Content of Enzyme-Modified Lecithin: Method 1 (1985),” which is incorporated by reference in its entirety. [0038] Examples of chemically modified lecithin include ACL and HDL. These chemical modifications were also intended to enhance the surfactant or emulsifying characteristics of the lecithin. ACL can be prepared by treating lecithin with acetic anhydride. Acetylation mainly modifies phospholipids into N-acetyl phospholipids. HDL can be prepared by treating lecithin with hydrogen peroxide, benzoyl peroxide, lactic acid and sodium hydroxide, or with hydrogen peroxide, acetic acid and sodium hydroxide, to produce a hydroxylated product having an iodine value preferably 10% lower than that of the starting material. Also preferably, the separated fatty acid fraction of the resultant product has an acetyl value of about 30 to about 38. [0039] EML, ACL and HDL are commonly used as wetting or emulsifying agents and are not normally expected to be biologically active in plants. The inventors demonstrated for the first time that they can deliver a variety of biological effects as described in the examples below. It is noted that the unmodified lecithin does not cause the same effects. It is known in the art that pure lysophospholipids, such as LPE, can cause some of the EML-induced effects disclosed herein. However, the same effects that EML has cannot be explained by the lysophospholipids contained therein. In comparison to pure lysophospholipids, EML is a much more complicated product that contains many other types of molecules, which render EML as a whole, a different product from pure lysophospholipids in terms of its constituents and chemical and physical characters. In the radish cotyledon bioassay described in the examples below, 20 mg/L EML was more effective than 20 mg/L LPE for the induction of hypersensitive response in terms of the activation of enzymes PPO and IAA oxidase, even though the total amount of lysophospholipids in 20 mg/L EML is much less than that in the 20 mg/L LPE. These data indicate that one or more non-lysophospholipid components or chemical/physical properties of EML are important for the effects observed. Furthermore, the fact that ACL and HDL, which are not enriched in lysophospholipids, were also able to induce the activity of IAA oxidase, is consistent with the notion that modified lecithin works differently from pure lysophospholipids. [0040] Lecithin can be obtained from a variety of animal and plant sources including egg yolks, soybeans, sunflowers, peanuts, sesame and canola. The source and process for producing lecithin and methods for enzymatically (e.g., by phospholipase A 2 ) or chemically modifying lecithin are known to the art. In addition, lecithin, EML, ACL and HDL are commercially available from a variety of sources such as Solae, LLC (Fort Wayne, Ind.). Examples of EML and chemically modified lecithin that can be used in the present invention can be found in Food Chemicals Codex, 4 th ed. 1996, pages 198-221; and 21 C.F.R. sec.184.1063, sec. 184.1400 and sec. 172.814, both of which are herein incorporated by reference in their entirety. [0041] In one aspect, the present invention relates to a method of improving the quality of harvested plant parts such as fruits, vegetables, flowers and tubers by treating the plant parts with an effective amount of modified lecithin. In a related aspect, the present invention relates to a method for retarding senescence and enhancing the storage and shelf life of the harvested plant parts by treating the plant parts with an effective amount of modified lecithin. For these applications, modified lecithin can be applied to the plant part either before or after they are harvested. As discussed above, modified lecithin's effects on the quality, senescence and storage and shelf life of a plant part is believed to relate to its ability to reinforce the cell walls and provide additional structural integrity to plant tissues. A harvested plant part is usually limited to the water, nutrients and other essential molecules including its structural components that were there at the time of harvest. Over time, with the loss of these molecules and components, the plant part will undergo the senescence process, leading to the rotting and degradation of the plant part. By reinforcing the cell walls and providing more structural integrity, modified lecithin allows the plant part to better preserve the above molecules and components and thus improve the quality of the plant part. Further, the degradation and senescence process can be retarded as a result and the storage and shelf life of the plant part can be prolonged. For cut flowers wherein the stems are often immersed in water or a nutrient solution of some kind, the quality can still be improved and the shelf life be prolonged by including modified lecithin in the treatment solution. [0042] As used herein, the meaning of “quality of a plant part” depends on the plant part in question and refers to at least one of the following: the firmness (turgidity), color, flavor, scent and cracking of the plant part. The quality of the plant part is considered to be improved if the plant part is firmer (more turgid) and/or has a more desirable color, flavor or scent to an average consumer. For fruits, cracking reduction is also considered an improvement in quality. [0043] In another aspect, the present invention relates to a method for increasing the size, weight or both of a plant part by treating the living plant or the plant part thereof with an effective amount of modified lecithin. The size of a plant part refers to its volume. A skilled artisan knows how to measure and compare the size of a particular plant part. For example, for a substantially round fruit, diameter can be used as a measure of fruit size. For leaves that have similar thickness, the surface area can be used as an indication of leave size. The present invention is particularly useful for increasing the size, weight or both of various fruits, foliage, flowers and tubers. As shown in the examples below, as a result of the size increase, the number of marketable apples from an apple tree was increased. [0044] In a related aspect, the present invention relates to a method of enhancing root formation and development of roots on cuttings by treating the cuttings with an effective amount of modified lecithin. By enhancing root formation or development of roots on cuttings, we mean that modified lecithin can increase the number of roots, the overall length of the roots, or both. When a root is a commercial product itself, the method can be used to increase root production. Otherwise, the method of the present invention can be used to stimulate the growth and development of a plant. In particular, modified lecithin can be added to potting soil media to promote root formation and development. [0045] In another related aspect, the present invention relates to a method for enhancing tuber formation by treating a tuber plant or the tuber thereof with an effective amount of modified lecithin. By enhancing tuber formation, we mean that modified lecithin can increase the number of tubers. [0046] In another related aspect, the present invention relates to a method of stimulating turf grass growth by treating the turf grass with an effective amount of modified lecithin. Turf grass growth can be measured by any method familiar to a skilled artisan. For example, dry weight or biomass of the turf grass can be measured. [0047] In another aspect, the present invention relates to a method of improving the aesthetic attributes of a plant or plant part by treating the plant or plant part with an effective amount of modified lecithin to improve the overall health of the plant or plant part. Without intending to be limited by theory, the inventors believe that modified lecithin achieves this effect by reinforcing the plant cell walls and providing more structural integrity to plant tissues. This activity of modified lecithin is particularly useful in making the turf grass, bedding plants and other functional and decorative plants more appealing to consumers. [0048] In another aspect, the present invention relates to a method of increasing fruit set on or reducing fruit drop from a plant by treating the plant or a suitable part thereof with an effective amount of modified lecithin. Preferably, the whole plant is sprayed with a solution that contains modified lecithin. By increasing fruit set, the number of fruits available for harvest can be increased. By reducing fruit drop, one can reduce fruit loss and potentially increase fruit size as well. The method is particularly useful for fruits such as apples wherein a relatively large number of fruits tend to drop prior to harvest. [0049] In another aspect, the present invention relates to a method for protecting a plant, or plant part from a stress related injury. The method involves applying to the plant or plant part an effective amount of modified lecithin. By protecting a plant or plant part from a stress related injury, we mean one or more of the following: (1) complete prevention of the injury; (2) reduction in severity of the injury; (3) recovery from the injury to a higher degree; and (4) speedier recovery from the injury. [0050] As used herein, the term “stress-related injury” refers to an injury resulting from an abiotic and/or a biotic stress. “Abiotic stress” refers to those non-living substances or environmental factors which can cause one or more injuries to a plant or plant part. Examples of abiotic stress include but are not limited to chilling, freezing, wind, hail, flooding, drought, heat, soil compaction, soil crusting and agricultural chemicals such as pesticides, insecticides, fungicides, herbicides and fertilizers. “Biotic stress” refers to those living substances which cause one or more injuries to a plant or plant part. Examples of biotic stress include but are not limited to pathogens (e.g., fungi, bacteria and viruses), insects, nematodes, snails, mites, weeds, and physical damage caused by human and non-human animals (e.g., grazing, and treading). To protect a plant or plant part from stress-related injuries, modified lecithin can be applied at one or more of the following stages: (1) prior to exposure to stress; (2) during exposure to stress; and (3) after exposure to stress. Furthermore, modified lecithin can be used as an adjuvant for plant growth regulators, pesticides, insecticides, fungicides, herbicides, fertilizers and other agrochemicals that people normally use on plants wherein the use can deliver stress to plants. [0051] In practicing the present invention, a skilled artisan can readily determine whether to apply modified lecithin to only one particular plant part or the whole plant. Using stress-related injury protection as an example, if a stress condition only affects one particular plant part and the goal is to protect that particular part, it may be sufficient to treat that particular plant part with modified lecithin. [0052] Any suitable method of treating a plant or plant part with modified lecithin can be used in the present invention and a skilled artisan is familiar with these methods. Preferably, a plant or plant part is treated with a solution that contains modified lecithin. The preferred solvent for modified lecithin for the purpose of the present invention is water. However, other suitable solvents such as organic solvents can also be used. To treat a plant or plant part with a solution that contains modified lecithin, the plant or plant part can be sprayed with the solution, or it can be dipped or soaked in the solution. Other suitable methods of exposing a plant or plant part to modified lecithin can also be used. For cut-flowers in particular, they can be treated by dipping the cut end of the stem in a modified lecithin-containing solution. For treating underground roots or tubers, modified lecithin can be included in the soil. [0053] The dosage of modified lecithin to be applied for a particular application and the duration of treatment will depend on the type of plant or plant part being treated, the method modified lecithin is being applied, the purpose of the treatment and other factors. A skilled artisan can readily determine the appropriate treatment conditions. Generally speaking, when modified lecithin such as EML is delivered to a target plant or plant part in a solution, its concentration can range from about 1 ppm to about 20,000 ppm, from about 10 ppm to about 10,000 ppm or from about 25 ppm to about 5,000 ppm. The term “about” is used in the specification and claims to cover concentrations that slightly deviate from the recited concentration but retain essential function of the recited concentration. [0054] In addition to modified lecithin, one or more additives that enhance wettability, uptake and effectiveness of modified lecithin can be used together with modified lecithin in practicing the present invention. Examples of additives that can be used in the method of the present invention include but are not limited to ethanol and agricultural adjuvants such as Tactic™ (Loveland Industries, Inc., Greeley, Colo.). The additives can be present in amount of from about 0.005% to about 5% (v/v), from about 0.025% to about 1% (v/v), or from about 0.03% to about 0.5% (v/v) in a treatment composition or formula. [0055] By way of example, but not limitation, examples of the present invention are described below. EXAMPLE 1 Effects of EML on Cotyledon Expansion and Hypersensitive Response Enzymes [0000] Materials and Methods [0056] The soy EML (Precept™ 8160™), ACL (Precept™ 8140™) and HDL (Precept™ 8120™) used in this example were purchased from Solae, LLC (Fort Wayne, Ind.). The egg EML was purchased from Primera Foods, Cameron, Wis. [0057] Seeds of Raphanus sativus L. cv. Cherry-Belle were germinated in darkness at 24° C. for 40 h in Petri dishes containing filter paper wetted with distilled water. The smaller of the two cotyledons was excised, the fresh weight determined, and 10 cotyledons placed adaxial side down on filter paper in Petri dishes containing 7.5 mL of phosphate buffered saline (PBS, 2 mM, pH 6.0) and the compounds to be tested at 20 mg/L. Cotyledons were then incubated under continuous illumination up to 72 h at 24° C. or 25° C. and the increase in fresh weight determined. Chlorophyll content was determined after extraction of tissue into 80% EtOH (containing butylated hydroxytoluene 10 mg/L) and quantified using the equations Chl a=(13.95A663)-(6.88A647) and Chl b=(24.96A652)-(7.32A663) as described by Lichtenthaler, H K ( Methods in Enzymology 148:350-382, 1987). IAA oxidase, PAL, PPO and POD activity were determined as described by Kato, M et al. ( Plant and Cell Physiology 41:440-447, 2000) and Li, X et al. ( Plant Science 164:549-556, 2003). [0000] Results [0058] In order to remove variability from the bioassay—due presumably to temporal changes in the concentration of root-derived cytokinins in cotyledons—the bioassay procedure was modified to routinely include 0.2 mg/L (approximately 1 μM) kinetin in the background. [0059] Cotyledon expansion growth: The effect of soy EML in the presence of kinetin on expansion growth was investigated and the results are shown in Table 1. In the presence of kinetin, soy EML resulted in an increase of cotyledon expansion growth relative to the control. TABLE 1 Effect of soy EML on kinetin-induced cotyledon expansion in radish. Ten cotyledons were incubated on filter discs wetted with 2 mM PBS (pH 6.0) containing either kinetin (20 mg/L) with or without EML (all 20 mg/L). Cotyledons were incubated under continuous illumination in incubation chamber at 25° C. for 72 h and the change in fresh weight and chlorophyll content determined. Change in Chlorophyll Chlorophyll fresh weight a + b a + b Chlorophyll Treatment (mg) % of control (μg/cotyledon) (mg/g FW) a/b Control 10.11 ± 1.33 100 31.57 ± 0.31 2.12 0.75 ACC  2.56 ± 0.39  25 35.90 ± 6.13 5.40 0.83 Kinetin 15.49 ± 1.81 153 54.10 ± 7.03 2.17 0.87 Kinetin/EML 18.59 ± 1.13 184 58.44 ± 5.76 2.47 0.93 [0060] In a similar experiment with cucumber cotyledons, the effect of EML on cotyledon expansion growth was tested with both soy and egg EML. As shown in Table 2, both soy and egg EML increased the cotyledon expansion growth. TABLE 2 Effect of soy and egg EML on expansion growth of cucumber cotyledons. Cotyledons were incubated on filter discs wetted with 2 mM PBS buffer (pH 6.0) containing kinetin (0.2 mg/l) with or without the lecithins (20 mg/L). Cotyledons were incubated under continuous illumination in an incubation chamber at 25° C. for 72 h and the change in fresh weight determined (n = 3). Treatment Change in fresh weight (%) % of control Control 199.6 ± 1.0 100 Soy EML  232.0 ± 16.6 116 Egg EML 245.4 ± 3.1 123 [0061] In a separate experiment, the effect of EML, ACL and HDL on cotyledon expansion growth were tested. All these modified lecithins increased the cotyledon expansion growth (Table 3). TABLE 3 Effect of soy EML, ACL, and HDL on expansion growth of radish cotyledons. Cotyledons were incubated on filter discs wetted with 2 mM PBS buffer (pH 6.0) containing kinetin (0.2 mg/L) with or without the lecithins (20 mg/L). Cotyledons were incubated under continuous illumination in an incubation chamber at 25° C. for 72 h and the change in fresh weight and chlorophyll content determined (n = 3). Treatment Change in fresh weight (mg) % of control Control 12.60 ± 2.04 100 HDL 14.39 ± 2.09 114 ACL 15.11 ± 2.15 120 Soy EML 14.55 ± 2.69 115 [0062] PAL (EC 4.3.1.5) activity: Ethylene is produced by plants in response to a variety of stresses, including wounding (Kato, M et al. Plant and Cell Physiology 41:440-447, 2000). Assuming the stress is of sufficient intensity and duration plants will also begin to show signs of senescence. This notwithstanding, stress is a common daily feature of plant growth and development and because plants are generally immobile they require mechanisms to cope with “normal” day-to-day stress. This is achieved by a system of built-in defense mechanisms. One of these systems involves PAL (EC 4.3.5.1) and activity of this enzyme increases when plants are wounded or exposed to pathogens and/or elicitors. Activity of PAL is also light regulated so transfer of dark-grown seedlings to light would be expected to increase enzyme activity. To determine whether EML acts as an elicitor in a hypersensitive-type response, the activity of PAL in radish cotyledons after exposure to soy EML was investigated and the results are shown in FIG. 1 . [0063] EML caused a rapid but transient increase in protein content similar to that observed in kinetin-treated cotyledons. In this treatment, protein content started to decline after 6 h. In ACC-treated cotyledons protein accumulation was delayed and reached a maximum only 24 h after exposure to light. In all cases, accumulation of protein was associated with increased PAL activity. [0064] In EML-treated cotyledons, the increase in PAL was ballistic whereas it was progressively delayed in ACC, control, and kinetin-treated cotyledons. This observation provides strong evidence for a role for EML as an elicitor capable of stimulating PAL. [0065] Short-term kinetics of PAL induction by soy EML confirms that PAL activity was increased in EML-treated cotyledons ( FIG. 2 ). Thus, EML activates PAL and likely increases the pheylpropanoid content of growing radish cotyledons. Increased lignin deposition can therefore be expected and lead to the retardation of expansion growth without influencing chlorophyll accumulation. To test this possibility, cotyledons were supplied kinetin (to promote expansion) together with EML and lignin content was determined. Lignin was quantified by measuring the amount of lignothioglycolic acid (LTGA) in extractive-free tissue samples prepared from the cotyledons treated with or without EML as described by Chen, M and McClure, J W ( Phytochemistry 53:365-370, 2000). The results in FIG. 3 show that by 72 h EML-treated cotyledons contained substantially more LTGA. [0066] These results, together with induction of PAL ( FIGS. 1 & 2 ) and POD ( FIG. 4 ) activity support the idea that EML acts as an elicitor and causes affected tissues to increase the biosynthesis of phenolic esters and lignin. [0067] POD (EC 1.111.1.7) activity: POD (EC 1.11.1.7) has been implicated in lignin formation at the step of polymerization of monolignols (Grisebach, H, Lignins, In: The Biochemistry of Plants Vol 7, Secondary Plant Products, Conn E E (ed.) Academic Press, New York, pp 457-478, 1981) and induction of POD activity following wounding has been demonstrated for a number of species (Kato, M et al., Plant and Cell Physiology 41:440-447, 2000; and references therein). To determine the effect of EML on induction of POD, activity of this enzyme was monitored during the 72 h incubation period after exposure to soy EML (20 mg/l) and the results are shown in FIG. 4 . EML increased POD activity by approximately 15% (relative to control) within the first 6 h of incubation. Thereafter, POD activity declined in all treatments. The increase in POD activity at 48 and 72 h is a normal event in expansion growth and signifies the onset of organ maturity and the commencement of senescence. At this developmental stage, POD activity was lowest in kinetin-treated cotyledons followed by those treated with EML. Highest POD activity was measured in control and ACC-treated cotyledons. This suggests that EML can slow the progression of cotyledon leaf development into the senescence phase. [0068] Although the above result points to induction of components of the hypersensitive response pathway by EML they give no indication of a systemic-type mechanism. To determine whether in fact the response is systemic, mung bean seedlings were supplied solutions of EML via the transpiration stream, incubated for periods up to 72 h, and PAL activity of the cotyledon leaves determined. The results in FIG. 5 show that treatment of mung bean seedlings with EML via the transpiration stream did not change PAL activity in leaves. Thus, we can conclude that EML does not induce a typical systemic-type response. [0069] PPO (EC 1.14.18.1): Like PAL and POD, PPO is an important enzyme catalyzing lignin biosynthesis in plants. In the radish system, PAL and POD are induced by exposure to soy EML and as shown in FIG. 6 , PPO was also induced and activity was at a maximum 48 h after treatment. By contrast, LPE did not induce PPO activity as EML did and ACC appeared to suppress PPO activity. In untreated and kinetin-treated cotyledons, enzyme activity appeared to increase gradually over time. [0070] IAA Oxidase activity: IAA homeostasis is an important process contributing to correlative control of plant growth and development. Generally, IAA is synthesized in the apices and in shoots; apically derived IAA is basipetally transported. It is the basipetal movement of IAA that modulates process such as apical dominance, adventitious rooting, tropistic responses etc. In the presence of soy EML, activity of IAA oxidase is increased whereas LPE has no apparent effect on this activity ( FIG. 7 ). [0071] POD activity and IAA oxidase are involved in lignin biosynthesis and auxin catabolism respectively. A number of growth retardants have been shown to reduce elongation growth by impacting POD and IAA oxidase activities. In addition, increased IAA oxidase activity has been observed in tissues exposed to pathogens. Thus, the data in FIG. 7 indicates that EML acts as an elicitor and probably contributes to increased phenolic acid production and/or lignification and modulates endogenous IAA by impacting IAA oxidase. To determine whether this effect was due to enzyme modification of the parent lecithin, unmodified (soy lecithin) and modified (EML, ACL and HDL) lecithins were compared. [0072] The data in FIG. 8 illustrate that EML, ACL and HDL were very effective inducers of IAA oxidase activity. The unmodified lecithin appeared to have little or no effect on IAA oxidase activity. EXAMPLE 2 Impact of EML on Grape and Apple Firmness (Turgidity) [0073] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0074] FIG. 9 illustrates the ability of 2000 ppm soy EML aqueous solution to improve grape fruit firmness when applied pre-harvest. Applications of 2000 ppm soy EML were made in April 2003 using a hand operated mist bottle spraying to fully cover the grape clusters with tiny droplets that adhered securely to the fruits without running off. Harvesting took place approximately 2 weeks post application. 25 berries from each cluster were removed from pre-determined sectors of the rachis (with stem cap attached) and measured for firmness using a Firmtech firmness and diameter analyzer (BioWorks, Stillwater, Okla.). As shown in FIG. 9 , EML treatment increased the firmness of the grapes. [0075] FIG. 10 illustrates the ability of 2000 ppm soy EML aqueous solution to improve apple fruit firmness when applied pre-harvest. Applications of 2000 ppm soy EML were made on Sep. 18, 2003 with a commercial air blast sprayer to fully cover the apple clusters with tiny droplets that adhered securely to the fruits without running off. Harvesting took place approximately 2 weeks post application. 20 apples were selected at random from the harvested sections and measured for firmness using a Firmtech firmness and diameter analyzer (BioWorks, Stillwater, Okla.). As shown in FIG. 10 , EMIL treatment increased the firmness of the apples. EXAMPLE 3 Impact of EML on Tomato Storage Life [0076] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0077] FIG. 11 illustrates the ability of 1000 ppm soy EML aqueous solution to improve vine-ripe tomato fruit storage when applied pre-harvest. Applications of 1000 ppm soy EML were made in July 2003 to mature green tomatoes using a CO 2 backpack sprayer spraying to fully cover the tomato fruit with tiny droplets that adhered securely to the fruits without running off. Harvesting took place approximately 7 days post application. Red ripe fruit remained under light conditions and ambient room temperature for 20 days after harvest with technicians removing unmarketable fruits (fruits showing water-soaking, sour rot, and/or mold). As shown in FIG. 11 , EML treatment increased the percentage of total marketable fruit. EXAMPLE 4 Effect of EML on Size, Color and Weight of Fruits and Vegetables [0078] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0079] FIGS. 12-16 illustrate the sizing and color impact of soy EML applied approximately 2 weeks prior to harvest in Fowler, Calif. on Summer Sweet peaches. 1000 ppm aqueous solution was applied using a hand operated mist sprayer to fully cover the fruit. Applications took place on Jun. 25, 2003, and harvested on Jul. 8, 2003. Color and size measurements were determined using an optical sorting line at the UC-Davis Kearney Agricultural Station in Fresno, Calif. [0080] This was a Single Latin Square design, with each treatment occupying each available treatment position only once. One scaffold, or limb, was assigned a treatment. All treatments occurred once on each of 4 trees. Treatments were applied in late afternoon. Harvest took place on Jul. 8, 2003. Harvesters stripped all treated fruit from each scaffold and transported them to the Kearney Agricultural Station in Fresno, Calif. Each repetition was run through an optical sorting line to separate fruit by color and size. Sizes range from 1 to 10, with 1 being the smallest most unmarketable fruit approximately 1.5 inches in diameter and 10 being the largest and greater than 3.5 inches in diameter. [0081] The effect of soy EML on the percentage of size 3, size 6-7 and size 9 peaches are shown in FIGS. 12 , 13 and 14, respectively. Treated fruit showed a smaller percentage in the low size category (#3) and much larger percentages in the bigger size categories (#6-9). Larger fruit is more valuable, especially when falling in the moderate to large range of #6-7. Color also determines marketability. Treated fruit show higher percentages of fruit with moderate blush (40-100%) ( FIG. 15 ) surface, and with high blush (60-80%) ( FIG. 16 ). [0082] FIGS. 17-19 illustrate the sizing impact of soy EML, applied approximately 10% color break in Mendota, Calif. on red bell peppers on Jul. 23, 2003. 500 ppm aqueous solution was applied using a hand operated mist sprayer to fully cover the fruit. This was a Randomized Complete Block Design with 8 replications. Application took place in the early morning after sunrise. Temperatures were approximately 72° F. and humidity was approximately 50%. Droplet dwell time was in excess of 30 minutes. As can be seen from FIGS. 17-19 , treated fruits were longer, wider, and heavier than the control fruits. [0083] FIGS. 20 and 21 illustrate the weight and sizing impact of soy EML applied approximately 3 weeks prior to harvest on McIntosh apples in Gays Mills, Wis. 1000 ppm aqueous solution was applied using a hand operated mist sprayer to fully cover the fruit. Application took place on Sep. 9, 2003, and harvested Sep. 30, 2003. This was a Single Latin Square design with each treatment occupying only one quadrant in each of 4 tree replicates. [0084] Applications were made in the mid afternoon with an air temperature of approximately 68° F. and clear skies. Droplet dwell time was in excess of 30 minutes. Treated fruit were larger (diameter) and heavier than the control fruit. As illustrated in FIGS. 20 and 21 , respectively, soy EML treatment led to an increase in weight and diameter of the McIntosh apples. EXAMPLE 5 EML Enhances Tuber Size and Yield [0085] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0086] To determine the effect of EML on potato tuber size and yield, a field trial was conducted. Dark Red Norland potato plants, grown at Muck Farms, on muck soil, near Lake Mills, Wisconsin, were sprayed with three levels of EML in aqueous solutions. Crop growth at spray application, two weeks before vine kill and four weeks from harvest, was excellent. Tubers were at a stage of rapid accumulation of food stuffs and were rapidly increasing in size. [0087] Field plot design: Uniform part of the field away from the road or other traffic was selected for these experiments. Single row plots, 20 ft long were used. There were five replicates for each treatment and the plots were separated by single untreated rows to avoid any spray drift. [0088] EML levels tested and spray parameters: Three EML levels, namely EML 100 ppm, 250 ppm and 1000 ppm were applied to plant foliage. No adjuvants were used. There were two spray applications. The first application was about two weeks before vine kill where as the 2 nd application, 10 days later, was only five days before vine killing. [0089] CO 2 powered backpack sprayer, using nozzle providing fine droplet size, was used. Liquid was applied at of 20 gallons/acre. It enabled a good foliar coverage. [0090] Vine killing: About two weeks before harvest, the plants were sprayed with Paraquat herbicide to kill vines and to prepare for harvest. [0091] Harvest: Central 15 ft of the each plot was manually harvested to determine potato yield. All the tubers were collected, dusted off and weighed. After washing and drying, based on their size, the potatoes w ere classified into <4 oz, 4 to 10 oz and over 10 oz. Each size class was visually further divided, based on their skin color, into premium, acceptable and poor. Potatoes in each class were counted and weighed. Any rotting or damaged potatoes were then discarded. [0092] As shown in Table 4, all three EML levels tested increased potato tuber yield. EML 100 ppm provided the largest marketable yield increase of 36.8%. [0093] As shown in Table 5, all three EML levels tested increased potato tuber size. EML 100 ppm provided the largest increase. TABLE 4 EML application to the foliage of potato plants of cultivar Dark Red Norland enhances tuber yield. Marketable tuber yield Treatment (Lbs/plot) % of untreated control Untreated Control 17.0   100% EML 100 ppm 23.3 136.8% EML 250 ppm 18.9 110.3% EML 1000 ppm 21.6 127.0% [0094] TABLE 5 EML application to the foliage of potato cultivar dark Red Norland enhances tuber size. Tubers <4 oz. Tubers >4 oz. (expressed as % (expressed as % Treatment of total yield) of total yield) Untreated Control 32.8% 67.2% EML 100 ppm 24.2% 75.8% EML 250 ppm 27.2% 72.8% EML1000 ppm 25.2% 74.8% EXAMPLE 6 EML Enhanced Root Mass [0095] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0096] This example illustrates the ability of EML to promote root growth when incorporated with the sod substrate prior to placement in a hydroponic situation. On Jul. 12, 2003, 3 repetitions of cross-sectional slices measuring 6 inches by 12 inches from a sod mat were placed on a bed of powdered soy EML to coat the root mass. The mats were then placed in a hydroponic solution of ½ strength Hoagland's solution with aeration for 14 days. After 14 days, the mats were removed from solution and three 1-inch slices removed from the mid-section of each mat. The soil was washed from the roots and the shoot portion was sheared at the root shoot interface as to leave only the root portion behind. The root masses were air-dried and then weights taken. The results were shown in Table 6. [0097] In Table 6, each replication consists of three 1-inch by 6-inch cross-section slices of sod from a 6-inch by 12-inch mat in Hydroponic solution. Each replication number is the mean of the raw data root mass in grams of 6 square inches of sod. In all three replications, EML treatment increased the sod root mass. TABLE 6 Sod root mass in grams. Water Control Soy EML Replication 1 2.08 g 3.54 g Replication 2 2.10 g 3.08 g Replication 3 2.45 g 2.65 g Mean 2.21 g 3.09 g EXAMPLE 7 Effect of EML on Root Formation [0098] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0099] FIGS. 22-24 illustrate the impact of 20 ppm soy EML solution on mung bean root formation. 3.5 cm cuttings were placed in 6-inch test tubes containing solution for 4 days under constant light and approximately 70° F. After 4 days the newly formed roots were counted. Ten replicates were executed. FIGS. 22 and 23 are pictures of control and EML-treated roots at the end of the experiment. FIG. 24 shows the average number of roots in the control and EML-treated group at the end of the experiment. Treated mung bean cuttings showed approximately 50% increase in root number after 4 days of treatment ( FIG. 24 ). EXAMPLE 8 EML Enhanced Pod Set and Seed Yield in Soybean [0100] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0101] In soybeans ( Glycine max L), 43 to 81% of flowers produced fail to produce mature pods due to flower drop, before pollination, or fertilized, immature pod drop (Hansen and Shibles, Agronomy Journal. Vol. 70, January-February, 1978). Over the years, various growth hormones such as ABA, IAA, BAP and GA3 have been tested to enhance the pod set with various levels of success (Mosjidis et al., Annals of Botany 71:193-199, 1993). [0102] To determine the effect of EML on soybean pod set and seed yield, ten field trials were conducted with Glycine max L. soybean. Of these, two were large plot farmer's field trials and all others were small plot replicated field tests. Several different cultivars were used. Test sites had diverse growing conditions, ranging from Brownsville, Tex. to Cedar Falls, Iowa, covering the soybean belt as well as the areas where soybeans are grown only on a small acreage. [0103] In field tests, in Brownville, Tex., the plants were sprayed with various levels of EML, in aqueous solutions, at pre-flowering, early and peak flowering stages of plant development. In the subsequent field tests, based on these data, a single spray at peak flowering of plant growth was applied. [0104] Field plot design: In all field tests, wherever possible, uniform part of the field was selected for the experiments. Four row plots, 25 to 30 ft long were used. There were three to five replicates for each treatment. To avoid EML drift to the adjoining plots, only the center two rows were treated and used to record all subsequent data. At farmers field tests, plot size varied from 2 to 8 acres. [0105] EML levels tested and spray parameters: EML levels of 0, 10, 50, 100 and 500 ppm were applied to plant foliage. No adjuvants were used. [0106] CO 2 powered backpack sprayer, using nozzle providing fine droplet size, was used. Liquid was applied at 15 to 50 gallons/acre. It enabled a good foliar coverage. [0107] Pod set data: Pod set data were recorded on ten plants, selected at random, in each replicate about four weeks after the EML spray. All the growing pods on each of the selected plants were counted. [0108] Seed yield data: For seed yield data, the two center rows, treated with EML, were harvested using a combine harvester. Data were calculated based on plot size and compared to the untreated controls. [0109] In all ten field trials, soy EML was effective in increasing the pod set of soybeans. Depending on the specific cultivars, the concentrations of EML that were effective varied somewhat. As an example, the results from a trial conducted in Cedar Falls, Iowa are shown in Table 7 and Table 8. As shown in Table 7, the percentage increase in pod set was higher for cultivar Pioneer 92B38 than cultivar Kruger K-269. All concentrations of EML tested increased the pod set of cultivar Pioneer 92B3 8. For cultivar Kruger K-269, 10 ppm, 50 ppm and 100 ppm EML increased the pod set while 500 ppm EML did not. [0110] As shown in Table 8, with the exception of 10 ppm EML on cultivar Pioneer 92B38, all concentrations of EML tested increased the seed yield of cultivars Pioneer 92B38 and Kruger K-269. TABLE 7 Soybean field test in Cedar Falls, IA: EML increased pod set of Pioneer92B38 and KrugerK-269 Cultivars. % of % of Mean # of Mean # of Control Control Pods/Plant Pods/Plant Pioneer Kruger Treatment Pioneer 92B38 Kruger K-269 92B38 K-269 Untreated 16.5 27.0 100% 100% EML 10 ppm 22.5 28.0 136% 104% EML 50 ppm 27.5 31.5 167% 117% EML 100 ppm 23.5 30.0 142% 111% EML 500 ppm 26.0 26.0 158%  96% [0111] TABLE 8 Soybean field test in Cedar Falls, IA: EML increased soybean yield of cultivars Pioneer 92B38 and Kruger K-269. Yield (Bushels/Acre) Yield (Bushels/Acre) Treatment Pioneer Kruger Pioneer Kruger Untreated Control 32.88 23.78 100% 100% EML 10 ppm 32.78 25.24 100% 106% EML 50 ppm 35.18 27.04 107% 114% EML 100 ppm 35.58 25.14 108% 106% EML 500 ppm 33.50 25.64 102% 108% EXAMPLE 9 Effect of EML on Fruit Drop [0112] The EML used in this example was soy EML (Precept™ 8160™) obtained from Solae, LLC (Fort Wayne, Ind.). [0113] FIG. 25 illustrates the impact of soy EML on fruit drop when applied approximately 3 weeks prior to harvest on McIntosh apples in Gays Mills, Wis. 1000 ppm soy EML aqueous solution was applied using a hand operated mist sprayer to fully cover the fruit. Application took place on Sep. 9, 2003, and harvested Sep. 30, 2003. This was a Single Latin Square design with each treatment occupying only one quadrant in each of 4 tree replicates. [0114] Applications were made in the mid afternoon with an air temperature of approximately 68° F. and clear skies. Droplet dwell time was in excess of 30 minutes. McIntosh apple trees often drop a large portion of their fruit. As shown in FIG. 25 , treated fruit showed a much lower fruit drop rate. EXAMPLE 10 Protecting Plants from Stress-Related Injuries [0000] Materials and Methods [0115] The experiments were conducted in growth rooms located at the University of Wisconsin Biotron Facility (2115 Observatory Drive, Madison, Wis. 53706). Each growth room was 10 ft×10 ft where temperature, light quality and photoperiod were controlled. The lights were at about 8 feet above the floor. A solid bank of fluorescent tubes provides lighting, while humidification was provided by steam pipes injected into the intake vents approximately 1 foot below the ceiling on the walls adjacent to the door. The outflow ducts were located directly below the intake vents approximately 1 foot off of the floor. Within these growth rooms the plants were grown on benches approximately 3.5 feet off the floor. [0116] All plants mentioned were grown in 6-inch square plastic (HDPE) pots approximately 6 inches deep with one of several soil-less media as indicated in each individual experiment, unless otherwise noted. The seeds were planted four per pot, uniformly in each corner of the pot into Fafard's Super Fine Germinating Mix soil-less media (Fafard Corp., 1471 Amity Road, Anderson, S.C. 29621). Once planted the pots were placed in a growth room set at 80% relative humidity (RH), 25° C. ±2° C., 16 hour photoperiod and 400 uE of light at the top of the canopy. [0117] Soy EML (Precept™ 8160™) was purchased from Solae, LLC (Fort Wayne, Ind.). EML-containing solutions were prepared by mixing EML in water with aggressive agitation until EML was completely dissolved or suspended. Solutions containing specific concentrations of EML as indicated in Tables 9-12 were used to treat plants as described below. [0118] Soy EML was used to make solutions that were applied directly to the vegetative parts of growing plants. To simulate the calcium found in normal tap water, all EML-containing solutions contained 1 mM of CaCl 2 . In some cases, 0.032% Tactic™ (Loveland Industries, Inc., Greeley, Colo.), a combination of an organo-silicone and a synthetic latex, and in others, ethanol, was further added to the EML-containing solution to facilitate wetting of the plant surface by the solution. The solution was applied to the plants by spraying with a hand held, manual spray bottle, similar to those used to dispense household cleaners. [0000] Results [0119] Chilling Stress Alleviation in Field Corn with a Pre-stress Application of EML: Four seeds of Golden Harvest field corn (F-1 hybrid, H-2387) were planted in six-inch square plastic (HDPE) pots. Fourteen days after planting, all the four plants in each pot were sprayed with 500 ppm of EML solution without any adjuvants or with water, which served as control. For each replicate, pots with plants matching in growth and development were selected. To ensure statistical validity, control and treatment were assigned to pots, at random. After spray, the plants were allowed to sit under ambient conditions for six hours before being exposed to the cold stress. Cold stress was initiated at the beginning of night period by dropping the temperature to 0C and the day temperature warmed to 25° C. This day/night temperature (25/0° C.) was repeated for four days. At the end of four cycles the plants were returned to their original growing conditions (25/21° C., day/night temperature) and allowed to grow for an additional five days to determine the effect of the cold on growth and vigor. After five days of growth, the plants were harvested at the soil level with a scalpel and fresh weight of each treatment was taken and compared against that of the control pot. In this experiment, using 500 ppm EML, we observed an increase in fresh weight of 5.3% over the control. This would indicate a mitigation, or alleviation, of the cold stress that would allow the treated plants to resume normal growth rates more quickly. [0120] Treatment of Soybean Plants with EML to Alleviate Cold Stress: In this experiment, soybean cultivar KB 241(Kaltenberg Seed Farms, 5506 State Road 19, PO Box 278, Waunakee, Wis. 53597) was used. The soybeans were planted in the six-inch pots, as described earlier, but eight plants per pot, two per corner, uniformly spaced with respect to the four corners. The plants were grown in Scott's 366-P soil-less growing media (Scott's Corp., 14111 Scottslawn Road, Marysville, Ohio 43041) under conditions: 80% RH, 25° C. and 400 uE of light for a fourteen-hour photoperiod in a growth room. Six days after planting the plants were treated with EML in the manner as described above in “Chilling Stress Alleviation in Field Corn with a Pre-stress Application of EML.” In addition to the EML and CaCl 2 , Tactic, a common spray adjuvant, was added at 0.032% to improve wettability of the leaf surface by the spray solution. In this experiment, one half of each pot, four plants, were treated with a control spray and the other four with treatment (EML 500 ppm). Plants in two halves of pots were matched for size, growth and development. The assignment of the treatment and control was at random. Consistent with the previous experiment, the application was made six hours prior to the cold exposure, after which the pots were moved to a growth room under cold (0° C.) conditions for 72 hour. The RH was at 80% and 400 uE of light for a 14-hour photoperiod. At the end of three days the plants were returned to their original growing conditions at 25° C. ±2° C., 80% RH and 400 uE of light and harvested after 13 d growth. Harvest was consistent with that described in “Chilling Stress Alleviation in Field Corn with a Pre-stress Application of EML”: cutting the vegetative portion of the plant at the soil surface with a scalpel and measuring the fresh weight of the plants. In this experiment EML treatment prior to chilling stress led to a fresh weight increase of 22% over the water treated, paired control. This increase is indicative of mitigated stress during the cold period and increased vigor after the stress. [0121] Treatment of Field Corn Plants to Mitigate Drought Stress: Golden Harvest field corn (F1 hybrid, H-2387), planted in six-inch square plastic (HDPE) pots was used. The seeds were planted four per pot, uniformly in each corner of the pot into Scott's 366-P soil-less growing media (Scott's Corp. 14111 Scottslawn Road, Marysville, Ohio 43041). The plants were grown in a greenhouse for twenty days at normal growing conditions (27° C. ±2° C. daytime for 14 hours and 23° C. ±2° C. nighttime). Humidity was not controlled and six 600 W high pressure sodium lights approximately 4.5 feet above the growing benches were placed to provide supplemental light. These greenhouses are located at the University of Wisconsin Biotron (2115 Observatory Drive, Madison, Wis. 53706). After 20 days of plant growth in pots, drought stress was initiated by withholding water to the pots until two days after visual symptoms of wilting appeared. At this time, each pot was divided into two side-by-side sets of two plants, one side was treated with EML and the other side was treated with water (control). Pots were fully watered to release the stress on plants and were kept under good water conditions for 9 days. Plants were then harvested and fresh weight recorded. As shown in Table 9, 100 ppm and 500 ppm EML treatment following drought stress led to a fresh weight increase of 6.1% and 10.3% respectively over the water treated, paired control. TABLE 9 Fresh weight of corn plants treated with EML to mitigate the drought stress. Data are average of five replicates. Treatment Average Mass/Plant (g) EML (100 ppm) 32.68 Paired water control for the 100 ppm-EML 30.68 group EML (500 ppm) 33.61 Paired water control for the 500 ppm-EML 30.48 group [0122] Mid-Stress Application of EML to Mitigate Drought Stress on Corn Plants: Golden Harvest field corn (F1 hybrid, H-2387) planted in six-inch square plastic (HDPE) pots was used. The seeds were planted four per pot, uniformly in each corner of the pot into Scott's 366-P soil-less growing media (see details in “Treatment of Field Corn Plants to Mitigate Drought Stress” above). All the details in this experiment are the same as described above in “Treatment of Field Corn Plants to Mitigate Drought Stress” except that EML spray application was made at one day after visual wilting was seen as opposed to two days after wilting in “Treatment of Field Corn Plants to Mitigate Drought Stress.” Plants were harvested seven days after the release of water stress. As shown in Table 10, 500 ppm EML treatment following drought stress led to a fresh weight increase of 19.5% over the water-treated, paired control. TABLE 10 Fresh weight of corn plants treated with EML to mitigate the drought stress. Data are average of five replicates. Treatment Mean plant mass (g) EML500 ppm 25.07 Water Control 20.98 [0123] Mid- and Late-Stress Application of EML to Mitigate Drought Stress in Corn: The experiments above in “Treatment of Field Corn Plants to Mitigate Drought Stress” were repeated with Golden Harvest and Syngenta N60-N2 field corn plants. Details of the experiments and the stress conditions were the same. [0124] Twenty-one day old Golden Harvest and Syngenta N60-N2 field corn plants were treated with 500 ppm EML during and just before the end of the drought stress. Mid-stress application took place after one day of drought stress measured from the time when plants first showed the signs of wilting. The late-stress application took place after 2 days of drought stress measured from the time when plants first showed the signs of wilting. The plants were watered within one hour of the last treatment application. The experiment had four replicates for each treatment. Eight days after stress relief, the plants were harvested and data were collected. [0125] As shown in Table 11, EML application increased biomass in both Golden Harvest and Syngenta N60-N2 corn. This increase was more pronounced in Syngenta N60-N2 corn plants. Application at either mid- or late-drought period was effective. TABLE 11 The effect of EML application in mid- (one day after drought stress) and late-drought (two days after drought stress, which was just before stress relief) stress periods on fresh weight of Golden Harvest and Syngenta N60-N2 corn plants. % increase in fresh weight over control by 500 ppm EML Mid-drought application on Golden 13.0% Harvest corn plants Late-drought application on Golden 10.9% Harvest corn plants Mid-drought application on 28.9% Syngenta N60-N2 corn plants Late-drought application on 22.2% Syngenta N60-N2 corn plants [0126] Pre-stress Application of EML to Mitigate Cold Stress in Cucumbers: Fifteen-day-old Dasher variety cucumbers were treated with 500 ppm EML and 1000 ppm EML before exposing plants to cold stress. Plants were in 6-inch square plastic (HDPE) pots with 2 plants in a pot placed diagonally from each other in opposite corners of the pot. Both plants in the pot were sprayed with the same treatment. There were 6 replicates for each treatment. Plants were sprayed with treatment or water, allowed to dry and then placed in a 1-2° C. cold room in the University of Wisconsin Biotron (room 251B) for 14 to 16 hours. After cold treatment, plants were allowed to grow in normal temperature conditions for 8 days. Plants were then harvested and data were collected. A treatment of cucumber plants with EML at 500 ppm and 1000 ppm before chilling stress gave 3.5% and 16.3% increase in fresh weight respectively compared to water treated control plants. [0127] Post-stress Application of EML to Mitigate Cold Stress in Cucumbers: Experiment in “Pre-stress Application of EML to Mitigate Cold Stress in Cucumbers” was repeated except that the application of EML, was made after the cold stress and cold treatment was for a 24-hour period. [0128] Twenty-two day old Dasher cucumber plants were cold stressed by placing them in a 1-2° C. cold room in the University of Wisconsin Biotron (room 251B) for a 24 hour period. Immediately after removal from the cold room, the plants were sprayed with treatment or water control. Twenty days after treatment, plants were harvested and data were collected. At harvest time, the degree of damage and re-growth varied widely. However, EML treatment (500 ppm) gave 90.3% increase in biomass as compared to water treated control plants. [0129] Pre- and Post-stress Application of EML to Mitigate Cold Stress in Melons: Experiments in “Pre-stress Application of EML to Mitigate Cold Stress in Cucumbers” and “Post-stress Application of EML to Mitigate Cold Stress in Cucumbers” were repeated with melons. [0130] Thirteen-day-old Primo melons were treated with 500 ppm EML before or after being exposed to cold stress. At the time of treatment, the plants had one fully expanded leaf and one small leaf. The plants were sprayed with treatment solutions either prior to cold stress or right after cold stress. Cold stress was exposure of plants to 1-2° C. for a 12-hour period. Plants were in 6-inch square HDPE pots with 2 plants in a pot placed diagonally from each other in opposite corners of the pot. Both plants in the pot were sprayed with the same treatment. There were 3 replicates for each treatment. Eight days after treatment, plants were harvested and data were collected. At time of harvest, the degree of damage and re-growth varied widely. At the time of harvest, all of the old leaves showed very little to no damage, all plants had 2-3 new leaves, all seem to be healthy and growing from apical meristem, and flower buds were beginning to form on all plants. EML at 500 ppm was effective at recovery from stress when applications were made after the cold stress exposure (Table 12). TABLE 12 The effect of EML application before and after cold stress on fresh weight of Primo melons. % increase in fresh weight over control by 500 ppm EML EML treatment before cold 9.4% stress EML treatment after cold stress 11.4% [0131] Mitigation of Cold Stress in Tomato Plants: Experiments described in “Pre-stress Application of EML to Mitigate Cold Stress in Cucumbers” and “Post-stress Application of EML to Mitigate Cold Stress in Cucumbers” were repeated with tomatoes. [0132] Fifty-two-day old Florida 47 tomatoes were treated with 500 ppm EML or 1000 ppm EML before exposure to cold stress. At the time of treatment, the plants were about 42-48 cm tall. The plants were arranged in replicates: replicate I being the most advanced (at flowering stage) and the tallest and replicate 4 being the least advanced and shortest. Replicates 2 and 3 were in-between. There were paired four replications for water control. After spraying, the plants were allowed to dry and then put into a 1-2° C. cold room for 25 hours. Plants were left in the normal growing conditions for several days after the cold stress. At the time of harvest, the plants were about 55-65 cm tall. The lower (old growth) leaves were all very damaged and many had fallen off but all plants had significant new growth. EML applied at 500 ppm and 1000 ppm gave 4.4% and 12.7% increase in plant biomass over control, respectively. [0133] Although the invention has been described in connection with specific examples, it is understood that the invention is not limited to such specific examples but encompasses all such modifications and variations apparent to a skilled artisan that fall within the scope of the appended claims.
Methods of using modified lecithin to delivery various benefits to plants and plant parts are disclosed. Modified lecithins, applied to growing plants, can cause improvements in fruit and plant firmness, size, color and stability, in economically important fruits and vegetables.
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CROSS-REFERENCE TO RELATED APPLICATIONS This application is a 371 of PCT/EP2013/057325 filed on Apr. 8, 2013. PCT application PCT/EP2013/057325 filed on Apr. 8, 2013 claims the benefit of U.S. Provisional application 61/623,918 filed on Apr. 13, 2012. FIELD OF THE INVENTION This invention relates to snow removal devices, methods and systems. BACKGROUND OF THE INVENTION The removal of snow at airports is of social and economical relevance. Airport downtime costs are in the order of tens of thousands Euros per minute for hub airports. The scale of snow removal varies according to airport size and geographic location. The snow removal operation of Amsterdam Airport Schiphol (AAS) is taken as a reference case. AAS handles the following guidelines for their snow removal operation: 1. AAS remains open for air traffic as long as possible. 2. AAS strives to the least amount disruptions as possible for the airport operations. 3. After calamities the fight on snow and slipperiness has the highest priority. 4. All assigned staff will be employed for this purpose. At an airport the tarmac to be cleared can be categorized in runways, exits, taxiways and platforms. These can be released when they are cleared of snow and the tarmac again complies to the operating standards of AAS. A runway is fully in operation again when the entire surface is cleared of snow. This includes the exit at the head and tail of the runway, the second and third rapid exit, and the taxiway parallel to the runway. In FIG. 1 the definition of a runway, exit, rapid exit and a taxiway is schematically illustrated. The dimensions differ per runway, but the given dimensions in FIG. 1 give a good estimation of the size. The shoulders are not illustrated, typically they are a third of the width of a runway, taxiway or exit. A platform is the place where airplanes are parked during boarding, a schematic view of a platform is given in FIG. 2 . The coefficient of friction μ between an airplanes' tire and the runway must be greater or equal to 0.25. Where μ is defined as the ratio between the friction force and the normal force. If the coefficient of friction after clearing is smaller than 0.25 the runway has to be cleared again. This criteria is not equal for all airports. The US Federal Aviation Administration (FAA) advises a minimum μ of 0.26. The FAA advises US airports through Advisory Circulars. Some are guidelines and some are mandatory. AAS has different standards for runways, exits, taxiways and platforms. For runways these are: 1) At least one runway should be operational with a μ≧0.25 and with a guaranteed capacity of 30 starts or landings per hour. 2) 23:00-6:00 (local time): At unfavorable conditions a number of starts could be postponed until the runway is cleared of snow. 3) 5:30-23:00 (local time): Within 40 minutes after passing of the snow precipitation or freezing rain a second runway must be operational. For exits and taxiways the friction coefficient must be μ≧0.25 and the maximum thickness of the layer of contamination is 4 mm. Contamination is the collective for snow, slush, water and chemicals. For a platform there is no criterion for the surface friction. Depending on the location of the platform it must be completely or partially cleared of snow and ice. Airports have different kinds of equipment for snow removal. A Runway Sweeper (RS) is a transformed truck that removes the snow in three stages. First a blade plow plows the majority of the snow towards the side. Then a broom clears the tarmac of snow, which is compressed between the pores of the tarmac and finally a blower blows the last remains to the side. An example of a runway sweeper includes a truck with a hitched broom is called a Hitched Broom Truck (HBT). The function of the HBT is to brush the tarmac. An example of an HBT includes blade plows that have limited casting range and are not capable of displacing very deep or very hard snow. This has led to the development of rotating cutting devices with one or more rotating elements. All designs of Rotary Plows (RP) cut the snow by means of a rotating element on the right side and on the left side a blade plow. The function of this blade plow is to remove the snow from the vicinity of the landing lights and prevents the RP of damaging the landing lights. Potassium Formate (PF) is sprayed on the runway. The goal of PF is to decrease the freezing point of H 2 O. The concentration of PF in H 2 O is proportional to the decrease in freezing point, therefore PF is sprayed when the majority of snow is removed from the runway. For the removal of snow from runways, taxiways and exits there are two snow fleets used at AAS. The AAS snow feet includes the following vehicles and persons: 1 manager, 1 coordinator, 8-runway sweepers including operators, 1 blade plow including operator, 1 rotary plow including operator, 1 hitched broom truck including operator, and 1 sprinkler machine including operator. The manager has the general overview of a snow fleet and a coordinator controls the individual machines. A snow schematic view of the snow fleet in operation is given in FIG. 3 . In this example, if a snow fleet removes snow from a taxiway the number of runway sweepers is decreased to 5. The majority of the snow on a platform is removed by blade plows and the last remains by HBT's. In FIG. 2 a platform is shown, in addition to the route of the blade plows and HBT's, with the snow deposit area. Airports apply different kind of methods depending on the weather conditions. These methods are: 1) Preventive mechanical removal: When frost is expected any water pools that might be present are removed. This will be done by HBT's on runways, exits, taxiways and platforms. 2) Mechanical removal: In the case of snow, slush, hail or pieces of ice the removal will be done by a snow fleet. Slush is a mixture of ice and water. In case of dry or extreme snowfall, mechanical removal of snow is assumed to be better than spraying potassium formate. In the last case there is a chance that the dry snow might stick to the liquid and forms a layer difficult to remove. 3) Preventive spraying of potassium formate: The prevention of frost on runways, exits and taxiways. On the tarmac an amount of 25 g/m 2 of potassium formate will be sprayed. If hail precipitation is expected the amount will be increased to 40 g/m 2 . 4) Corrective spraying of potassium formate: The removal of hail, frost or frozen slush on the runway, exit and platforms. The amount of potassium formate to be sprayed is 40 g/m 2 . This is an emergency measure. 5) Corrective scattering of de-icing grains: The removal of ice from the tarmac, after which the mechanical removal method can start. This is an emergency measure. 6) Sand scattering: The sand will make the ice surface rough. This is a final emergency measure. In the early twentieth century snowplows made their entry due to the motorization. In 1927 for example the company Good Roads advertised for snowplows that could be mounted on every truck. The focus of improving snow removal is on four main criteria that include: 1) Decrease emissions. ACI Europe is the council of over 400 European airports. In 2009 ACI Europe launched the Airport Carbon Accreditation program. The member airports committed to the ultimate goal of becoming carbon neutral. A decrease of emissions will imply a decrease of fuel use. This means the required tank time per snowfall can be decreased which has a positive side effect on the operational costs. 2) Decrease costs. At the moment the capital expenditures (CAPEX) of a snow fleet are between 8 and 9 million Euros and the economic lifetime is 15 years. Furthermore the snow removal machines are dead capital for most time of the year. The current technology results in high operational expenditures (OPEX) due to two characteristics. One snow fleet includes 12 operators and 2 managers, the companion and the coordinator. A decrease of machines will lead to a decrease in labor costs. And the downtime costs of tens of thousands of Euros lead to high OPEX. A faster operation will decrease these downtime costs. 3) Decrease organizational complexity. FIG. 3 shows the formation of a snow fleet. It is essential the snow fleet holds this formation over the entire runway. This requires intensive training of the personnel. The main concern of the snow removal staff is to manage this organizational complexity. A decrease in the number of operators will simplify the operation. 4) Increase capabilities. An airport is mandatory to remove the Foreign Object Debris (FOD) from the runway. Examples of FOD are small stones, nuts and bolts. At the moment the FOD removal operation is done by other machines. A combination of to multiple tasks in one machine will have a positive effect on costs and the operational complexity. The current substitute technique and the improved technique will be assessed on these main criteria. The current substitute technique is heated pavements. Centerline lights indicate the centerline of the runway to pilots and are shown in FIG. 4 . These centerline lights are slightly sunk in the runway, but can still form an obstacle for plows. The dimensions of a center light are given in FIG. 4 . AAS noted in the winter of 2010/2011 a significant damage to center lights. The FAA and the US Department of Defense (DOD) combined their regulations for surface drainage design. The maximum transverse slope is 2% and is a trade off between drive comfort and drainage. FIG. 5 shows the consequence of the transverse slope. A plow, or multiple plows, must follow this slope. Airfield signage is intended to provide information and direction to pilots. For example, a sign tells the pilot he is on taxiway R and the arrow indicates him where he will intersect taxiway W 2 . According to the FAA, post-clearing operations must be conducted to ensure the visibility of airfield signage. The distance of these signs from the pavements edge depends on its size. According to the FAA this is between 3 and 18 meters, ranging from the smallest to the largest sign. All existing heated pavement technologies are characterized by the transfer of heat from an energy source to the tarmac. Geothermal energy is the most utilized energy source. In 2010, 423,830 TJ of geothermal energy was used globally. This is a yearly increase of 9.3% since 1995. In 2010 the fraction of geothermal energy used for snow melting applications was 0.44%, which is 1,845 TJ. The applications are limited to Argentina, Japan, Switzerland, Iceland and the United States. 78% of the total energy used for snow melting is applied in Iceland. The costs of energy for passive methods depends significantly on the available local natural resources. FIGS. 6A-6B show the basics of an aquifer thermal energy storage (ATES) system. In summer water from the cold aquifer can be applied for cooling and in winter this works vice versa. It contains at least two boreholes that lead to suitable aquifer layers where groundwater is stored. A suitable aquifer layer is high permeable and the groundwater it contains is flowing slow. ATES can be fully automated in order to minimize operational activities in winter. An additional advantage of a heating system is the reduction of seasonal temperature fluctuations. This will increase the lifetime of the tarmac. The input temperature of the groundwater from the warm aquifer in winter is about 15° C. at AAS. The required temperature of the heat transfer fluid for the most extreme snowfall in the past twenty years is 65° C. A conventional ATES system normally comprises a heat pump to heat the water up to a maximum of 40° C. If an extreme snowfall occurs additional heating by, for example, a boiler is required. It is assumed the ATES system can be installed during the normal renovation of the runways tarmac. Downtime costs due to installation are therefore excluded in the investment. Heated pavement technology is not competitive with the current technology based on the first two criteria, the decrease of emissions and costs. What is needed is a snow removal system and method that addresses the challenges to decrease emissions, decrease costs, and decrease the organizational complexity. Untouched snow is a material easy to handle. However once it is touched, mixed with chemicals and when it is aged it is not. The amount of energy on plowing is proportional to the mass of the snow in front of the plow. It is also the only variable that can be altered, since the dynamic friction coefficient between snow and tarmac is constant for a certain snow type. A decrease of emissions can therefore be realized by taking the snow directly off the tarmac. What remains is the energy on brushing and blowing. If the new technique can take off the snow directly from the tarmac and fulfills the μ≧0.25 criterion, brushing and blowing will become superfluous. The challenge to decrease the organizational complexity is a function of the snow removal operation. This complexity is a consequence of the amount of operators, that need to be managed under time pressure. If the amount of operators can be decreased this will lead to an organizational simplification. What is further needed is a system and method that enables other features than snow removal to be implemented. On a runway multiple tasks are performed. These tasks include FOD removal, friction measurements and tarmac status measurements. The most frequent and time-consuming runway operation is FOD removal. AAS for example removes its FOD every night. This requires several hours per runway, including exits and the parallel taxiway. SUMMARY OF THE INVENTION To address the needs in the art, a snow removal system is provided that includes a snow removal system having a compression module, where the compression module has a tubular casing with a snow inlet and a snow outlet, where the snow outlet can be a converging or straight cross-section tubular shape, where the tubular casing is perforated with air holes. The compression module further includes a conveyor screw that rotates on a shaft that is disposed concentric to the tubular casing, where the conveyor screw spans from the snow inlet to the snow outlet, where the conveyor screw is powered to move snow from the snow inlet to the snow outlet and compacts the snow to a compressed state at the snow outlet, where air from the snow is exhausted through the air holes, where the compressed snow is output from the snow outlet. The snow removal system further includes a conveyor belt disposed to receive the compressed snow from the snow outlet and is disposed to move the compressed snow at a velocity v 1 from the snow outlet to a location away from the compression module, and a moveable truss that houses the conveyor belt, where the movable truss supports the compression module, where the movable truss moves at a velocity v 2 , where the v 1 is a value that is great enough to remove the compressed snow away from the compression module when the truss moves at a velocity v 2 , where the conveyor screw motor turns the conveyor screw to output the compressed snow at a rate that incorporates the v 1 and the v 2 to ensure a capacity to move the compressed snow away from compression module by the conveyor belt is not exceeded. According to one aspect of the invention, the truss further includes a sweeper and a vacuum that are disposed behind the movable truss and inline with the compression module, where the sweeper sweeps snow from the snow-covered surface to the vacuum, where the vacuum outputs the swept snow to the conveyor belt. In another aspect of the invention, the truss further includes an anti freeze liquid sprayer, to where the anti freeze liquid sprayer deposits antifreeze to a surface removed of snow. In yet another aspect of the invention, the conveyor screw shaft has a hollow shaft that is perforated with air holes, where air from the snow is exhausted through the air holes. In yet another aspect of the invention, the conveyor screw shaft has a diverging shaft cross-section along the snow outlet. According to one aspect of the invention, the conveyor screw has a constant screw pitch or a decreasing screw pitch. In a further aspect of the invention, the movable truss comprises a driving truss or a towable truss. According to one embodiment the snow removal system includes a compression module having a tubular casing with a snow inlet and a snow outlet, where the snow outlet has a converging or straight cross-section tubular shape, where the tubular casing is perforated with air holes, the compression module further includes a conveyor screw that rotates on an axis that is disposed concentric to the tubular casing, where the conveyor screw spans from the snow inlet to the snow outlet, where the conveyor screw is powered to move snow from the snow inlet to the snow outlet and compacts the snow to a compressed state at the snow outlet, where air from the snow is exhausted through the air holes, where the compressed snow is output from the snow outlet. According to one aspect the current embodiment further includes a snow container that receives the compressed snow output from the snow outlet, where the snow container stores the compressed snow. In one aspect the snow container has a dumping container, or a snow cube exerting container. In another aspect of the current embodiment, the conveyor screw shaft has a hollow shaft that is perforated with air holes, where air from the snow is exhausted through the air holes. According to one aspect of the current embodiment, the conveyor screw shaft has a diverging shaft cross-section along the snow outlet. In yet another aspect of the current embodiment, the conveyor screw has a constant screw pitch or a decreasing screw pitch. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a schematic view of a prior art runway, exit, rapid exit and taxiway. FIG. 2 shows a schematic view of a prior art platform. FIG. 3 shows prior art schematic view of a snow fleet. FIG. 4 shows prior art center lights. FIG. 5 shows a cross sectional view of a runway, where the maximum height difference between the center and side of a 40 meters wide runway is 0.40 meters. FIGS. 6A-6B show ground water flow in an ATES during winter and summer. FIGS. 7A-7B show schematic views of the snow removal system with 7 A showing compression modules to remove the snow directly from the runway surface and deposit it on a conveyor, which transports the snow away from the runway, where the conveyor is suspended in a truss on wheels, and 7 B showing a sweeper and vacuum integrated with the snow removal system, according to embodiments of the current invention. FIG. 8 shows a schematic view of two snow removal systems that drive over a runway, according to one embodiment of the current invention. FIGS. 9A-9C show the dimensions of the compression module shown with axial airflow through snow due to an un-perforated casing, radial airflow through snow due to a perforated casing, and a graph of required torque with and without air holes, respectively, according to one embodiment of the invention. FIG. 10 shows a graph of the applied pressure in z-direction versus density at a deformation rate. FIG. 11 shows a graph of applied pressure versus density. FIG. 12 shows applied stress σ z and resulting shear and principal stresses. FIG. 13 shows unconfined compressive strength versus deformation rate. FIG. 14 shows the power needed to overcome pressure drop versus α for different compression ratios for the axial (solid lines) and radial (dotted lines) case. FIG. 15 shows a graph of the required power versus α and for different compression ratios in the radial and axial case. FIG. 16 shows the stresses due to compression on an infinitely small cube of snow. FIG. 17 shows the stresses on the screw due to compression, σ r is directed into the paper. FIG. 18 shows a graph of the tower needed to compress the snow versus α for different compression ratios for the upper domain (solid lines) and the lower domain (dotted lines). FIG. 19 shows a graph of the dynamic friction coefficient versus temperature. FIG. 20 shows a graph of the power needed to overcome the dynamic friction at the wall for μ d =0.05 at initial conditions. FIG. 21 shows a graph of the total power needed to compress the snow for R 1 =0.25 m, ρ 0 =100 kg/m 3 and ν machine =10 m/s. FIG. 22 shows a hydraulic diagram of the compression module drive and sensors, according to one embodiment of the invention. FIG. 23 shows Measurement principle of the Parker flow turbine meter SCFT-150-02-02. FIG. 24 shows a compression module and container system, according to one embodiment of the invention. FIGS. 25A-25C show different embodiments of the compression module having a converging casing and constant pitch screw, straight casing and diverging screw, and straight casing and decreasing screw pitch, respectively, where it is understood that any of the screw profiles may be hollow with air holes and any of the casing profiles may have air holes, according to different embodiments of the invention. DETAILED DESCRIPTION The current invention is a snow removal system, method and/or process that addresses the needs in the art, including removing all snow from the tarmac directly, decreasing the number of operators, increasing removal speed, and is capable of removing FOD. FIGS. 7A-7B show exemplary embodiments of the current invention, where compression modules form one plow on the front side, which is (preferably) perpendicular to the normal direction. In each compression module a conveyor screw is suspended. The conveyor screw compresses the snow to reduce the volume flow of snow by extracting the air from the snow. The majority of the snow is deposited through the conveyor screw onto the conveyor, this conveyor is suspended in a truss. This truss is driven by an engine. The conveyor deposits the compressed snow away from the runway surface, for example on the other side of the landing lights, as shown in FIG. 7A . In one embodiment, the conveyor is suspended in a truss on wheels. In one embodiment, the snow can be stored by the snow removal system without using the conveyor. FIG. 7B shows another embodiment of the invention, where a bush brushes or loosens remaining layers of (compressed) snow from (the pores of) the tarmac. A vacuum vacuums the loosened snow onto the conveyor. The compression modules can be decoupled from the truss. The machine further has the possibility to spray potassium formate on the runway. In one example, the potassium formate sprayer is behind the brush. In a further embodiment, the nozzles that spray could also be suspended on the truss. In one example, the snow removal system has a width of 20 meters and takes all the snow directly off the runway. An exemplary velocity of 10 m/s and a snow height of 10 cm the volume flow of fresh snow is 20 m 3 /s. The velocity of standard rubber conveyors is limited to 7 m/s and have a maximum width of 2.2 m. The internal friction angle of snow is about 15° and is density dependant, as is described in equation (3) below. A pile of snow is therefore steep instead of sand for example. The resulting height of the snow in the snow removal system is therefore about 1.5 m. By compressing the snow, the height and width of the truss can be decreased and more snow can be processed and stored by the snow removal system according to the current invention. In a further embodiment, the snow removal system has compression modules that are suspended to the truss by conventional mounting to enable suspending other modules, for example brushes, from the snow removal system. The present invention allows airports to reduce the costs of their winter operations by replacing a fleet of independently operated machines with 1 or 2 snow removal system machines of the current invention, each operated by one operator. FIG. 8 shows a machine driving forward with a velocity V 2 on a runway and depositing snow with velocity V 1 on the other side of the landing lights. One or more machines according to the invention could be used for snow or dirt removal as well as sweeping of runways, roads, freeways, parking lots, storage grounds, sidewalks or the like. FIG. 8 shows an example of how two machines could be used removing the snow from a runway. In this example, each machine could be a little wider than half the width of a runway. If the machine according to this invention is used for sweeping a runway then the velocity V 1 equals zero, thereby collecting the dirt on the conveyor. According to the current invention, the compression module reduces the volume flow of the removed snow. This leads to a significant decrease of the dimensions of the machine, which advances the technology in the art. In the compression module, a conveyor screw presses the snow through a casing. According to the current invention, there are three manners to compress the snow: a decreasing outer radius, an increasing inner radius and/or a decreasing pitch. An exemplary velocity of the machine is 10 m/s and an angular velocity of the screw of 750 RPM. In one embodiment, the dimensions of the compression module shown in FIGS. 9A-9B are: R 1 =0.15 m, R 2 =0.25 m, R axis =0.10 m and L=1 m. The power needed to achieve compression, excluding drive train losses, can be split in four components: pressure drop of air, compression of snow, the friction at the wall and the pumping of snow over a height. FIG. 9C shows a graph of the required torque for the compression module to compress snow and output the compressed snow for a tubular casing with and without holes, where the circle is the applied torque with holes and the cross the torque without holes. According to the current invention, the reduction of volume flow of snow equals the volume flow of air through the snow, thus a pressure drops needs to be overcome. For example, at typical velocities and dimensions the power needed to overcome this pressure drop is in the order of 35 kW per compression module, as is shown in FIG. 9C . The width of an example machine is about 20 m, meaning 40 compression modules and 1400 kW is needed to overcome the pressure drop due to the airflow. According to one embodiment, the casing is perforated with air holes, as is shown in FIG. 9B , the air is released perpendicular to the normal direction of the snow. The power needed to overcome this pressure drop is about 0.40 kW per compression module and 16 kW for the entire machine. According to the current invention, by removing the air through holes of the casing and/or hollow screw axis the required power to overcome the pressure drop through snow compression is reduced from 35 to 0.40 kW per compression module on a total of 54 kW per compression module. Here, the snow is compressed by removing air encapsulated by the water crystals of the snowflakes, where the snowflakes collapse to reduce the volume of the snow. During the snow compression, the snow crystals are deformed and the air encapsulated between the water crystals is released from the snowflakes and escapes through the holes of the casing of the compression unit or through the holes in a hollow conveyor screw shaft. According to the current invention, another component of the required power is the power to compress the snow. Snow falls at a density of 50-100 kg/m 3 . Due to the braking of inter-granular bonds the density can increase to 500 kg/m 3 , this is called the critical density. Due to creep deformation the density can increase further. According to the current invention, the compression module compresses the snow towards the critical density. In one example, the compression module requires a power of about 54 kW and a total power of 2160 kW at typical velocities and dimensions. According to the current invention, another component of the required power is due to friction at the wall. At high temperatures of 0° C. the friction is dominated by a film layer of water between snow and wall. A casing of a hydrophobic material can minimize this friction. At low temperatures of about −30° C. the friction is dominated by the plastic deformation of snow grains at the wall and is typically higher than at high temperatures. In one example, the compression module requires a power of about 15 kW and a total power of 600 kW at typical velocities and dimensions. Snow is a complex three-phase material and is created in the air. Water is present in air in the form of water vapor. If air rises from warm lower layers to cold upper layers due to a density difference it will be cooled. This decrease of temperature leads to a decrease of water vapor air can contain. When the maximum concentration of water vapor in air is reached, the surplus of water vapor will condensate. Sublimation into a nuclei of ice occurs at temperatures below −10° C., but can still occur at about −3° C. Once a nuclei of ice is formed the growth is dominated by attachment kinetics in combination with two transport processes, mass and heat diffusion. The origin of diversity in falling snow is due to three sources. The first source is the variation in crystal size at nucleation. The second source is the variation in trajectories of each snowflake, i.e. each snowflake has a unique trajectory. The third source is due to temperature heterogeneities along each trajectory. These sources prescribe that each snowflake experiences unique circumstances during growth, resulting in unique snowflakes. An international classification for seasonal snow on the ground to distinguish different kinds of snow has characteristics of the microstructure that include: grain shape and grain size and bulk properties of snow are density (σ), liquid water content (θ w ) and the snow temperature (T s ). The mechanical properties of snow are strongly dependent on the ice and air spaces. This microstructure of snow is a complex matter, since each snowflake is unique as discussed in the previous subsection. The microstructure of snow changes over time, making the description of the mechanical properties of snow a daunting task. The grain size can differ from very fine (<0.2 mm) to extreme (>5.0 mm). Since only precipitation particles are considered, the distinction in grain shape is irrelevant. The liquid water content is the mass or volumetric percentage of water in liquid phase within the snow. The density is easily measured and is the most common quantity to identify snow. It is however a bulk property and it only provides a coarse prescription of the snow microstructure. The specific surface area (SSA) of snow is an important parameter for the characterization of porous media and is used more frequently in recent snow research. Here, the SSA and the intrinsic permeability provide a good framework in classifying snow. The density of fresh snow varies from 50 to 100 kg/m 3 . Under loading snow easily deforms, these high density changes are due to the collapse of pores resulting from braking of inter-granular bonds. The density tends to an asymptotic value of about 500 kg/m 3 in rapid confined compression. This density is called the critical density. Due to creep deformation the density of snow can increase further and above 830 kg/m 3 it is called ice. The compressive strength is determined by the microstructure of snow, which is made out of a network of ice grains. Deformation can occur plastically through the slip of individual ice grains or brittle through the disjointment of ice grains. Here, the junction between these two deformation mechanisms is made by a critical compressive velocity on the order of 0.01 mm/s. This is shown in FIG. 14 . At values above this compressive velocity brittle deformation is dominant. In one embodiment, the snow removal machine operates at 1-10 m/s, implying brittle deformation dominates. FIG. 10 clearly indicates brittle deformation as the dominant deformation process. It suggests the compressive strength cannot be specified by a function, but through a domain. Here, the upper boundary of this domain is given by equation (1) and the lower boundary by equation (2). σ u =p u e a u ρ′   (1) σ l =p l e a l ρ′   (2) where p u =900 Pa and p l =100 Pa are the fictitious compressive strength of the respectively upper and lower boundary at zero density. The coefficients are a u =14.84 m 3 /Mg and a l =17.403/Mg. The unit of ρ′ in these equations is Mg/m 3 . The domain is based on eleven data sets for strain rates between 10 −4 and 10 −2 s −1 . The strain rates in this example are between 0.1 and 0.5 s −1 , indicating the domain is valid for higher strain rates. Results are shown in FIG. 11 , where two stress conditions in z-direction are shown. The internal friction angle of snow is measured and is given in equation (3). φ=−0.016ρ+17  (3) where φ is the angle in degrees. FIG. 12 indicates the stresses in first normal direction and z-direction are almost equal due to the small internal friction angle. The obtained results of the friction angle and compressive strength provide the possibility to calculate the shear strength of snow. The shear strength σ s of FIG. 12 can be calculated by using equations (1), (2) and (3). The upper and lower boundary of this result is given by the straight lines in FIG. 13 . This is in good agreement with the shear strength of equation (5) to indicate cohesion, which is explained below. The relationship between the three principal stresses in the normal directions is shown in FIG. 12 . This relationship is based on experiments. σ 2 =K 0 σ 1 =σ 3   (4) where K 0 is approximately 0.12. The microstructure of snow changes in time, i.e. snow ages. Four distinct process that causes the aging of snow include sintering, interlocking, capillarity and freezing. During sintering the number of contact points between snowflakes increases. Interlocking occurs due to the interlocking of snowflakes. Capillarity plays a role when the liquid water content is greater than zero and freezing is relevant when the liquid water content of snow refreezes. The unconfined compressive strength of snow of different ages are measured. The unconfined compressive strength of the snow samples increased by a factor 10 as they sintered at constant density, as can be seen in FIG. 13 . The age of snow is therefore important information. It is difficult to make a snowpack of fresh dry snow, such as a snowball. This is due to a lack of sufficient inter-granular bonds between snow grains. When the number of bonds between grains increases due to aging it might be possible to make a snowball. For example when the temperature rises, the liquid water content of the snow increases. This leads to a stronger capillary bonding and a higher cohesion. The shear strength is a good measure for the cohesion of a snowpack. Based on the previous findings the shear strength should be a function of a parameter, which describes the microstructure of the snow. In literature however the shear strength is a function of density. In avalanche forecasting the shear strength is a criteria for whether an avalanche will occur. Shear strength is suggested to be a function of the dry density and the liquid water content and is given in equation (5). σ s =Kρ dry a e bθ w   (5) where σ is the shear strength (N), K is an experimentally determined coefficient and is 9.40×10 −4 for new, decomposed and dry snow. ρ dry is the dry density, a is 2.91 m 7.73 /kg 1.91 s 2 and b is −0.235 (% −1 ). The liquid water content in FIG. 13 equals zero. Adhesion is the tendency of non-identical materials to stick to each other. The number of grain contacts of snow on the supporting surface influences the strength of the attachment. The temperature is an important parameter in the magnitude of adhesion. At temperatures between −6.7° C. and 0° C. the liquid water content is sufficient to increase the contact of snow to its support surface. The adhesion of snow to a support surface should be limited in the design of snow removal equipment. A hydrophobic material would be beneficial to limit adhesion. The design of an example of one embodiment of the compression module is provided. The determination of the design is based on four parts: the pressure drop due to the air flow in snow, the deformation of snow, the determination of the friction of snow at the wall and the pumping of snow over a height In the conveyor screw the decrease of volume flow of snow equals the volume flow of air through the snow towards the outlet. This implies a pressure drop has to be overcome. The order of the pressure drop can be calculated, where the intrinsic permeability for different types of snow is determined assuming Darcy's law. The intrinsic permeability of compacted fresh snow equals 2.10 −9 m 2 . An estimation of the order of the pressure drop for the conveyor screw can be made by the following assumptions: screw blades do not contribute to the pressure drop laminar flow Darcy's law is stated in equation (6). υ = - k 0 μ air ⁢ ∇ p ( 6 ) where ν is the superficial velocity, k 0 the intrinsic permeability of snow, μ air the dynamic viscosity of air and p is the pressure. There are two possibilities for the air to leave the compression module. The first possibility is that the air is removed axially at the outlet. The second possibility would be a radial airflow. In this case the casing of the compression module will be perforated. These two possibilities are shown respectively in FIGS. 9A-9B . The superficial velocity is defined as the volume rate of flow divided through a cross-sectional area of the solid plus gas. Darcy's equation for both cases is given in equations (7) and (8) Δ ⁢ ⁢ p axial = Q air ⁢ μ air ⁢ L A axial ⁢ k 0 ( 7 ) Δ ⁢ ⁢ p radial = Q air ⁢ μ air ⁡ ( R 2 - R 1 ) A radial ⁢ k 0 ( 8 ) where Δ paxial is the pressure drop in the axial case, L the length of the compressing part of the screw conveyor, Δ pradial is the pressure drop in the radial case, R 1 the radius at the start of compression and R 2 the radius at the outlet. Q air is the volumetric air flow and is given in equation (9) Q air =ν snow ( A 1 −A 2 )=ν snow A 2 ( c− 1)  (9) where c=A 1 /A 2 is the compression ratio and ν snow is the axial velocity of the snow in the compression module. The axial cross-sectional area is given in equation (10) and the lateral area is given in equation (11). A axial = 1 L ⁢ ∫ o L ⁢ π ⁢ ⁢ ( R 2 - R axis 2 ) ⁢ ⅆ z ( 10 ) A radial = 1 2 ⁢ ( A outer + A axis ) = 1 2 ⁢ ( ∫ o L ⁢ 2 ⁢ π ⁢ ⁢ R ⁢ ⅆ z + 2 ⁢ π ⁢ ⁢ R axis ⁢ L ) ( 11 ) Where R is a function of z, the radius R 1 =0.25 m and R axis =0.10 m. A choice for α and c will fix R 2 and L. The required power versus α and for different compression ratios in the radial and axial case is given in FIG. 15 . It is clear there is a significant difference between the required power between the axial and radial case. Equation (6) is only valid for laminar flow. The Reynolds number for flows through porous media is: Re = ρ air ⁢ υ ⁢ ⁢ l g μ air ( 12 ) where ρ air is the density of air, ν the superficial velocity and l g the characteristic length of the pores. It was stated above the grain size of a snowflake ranges from 0.2 to 5.0 mm, in this case l g is chosen to be 0.1 mm, since it concerns snowflakes in a compressed state. The domain Re<2 corresponds to laminar flow and Re>100 corresponds to turbulent flow. At a velocity of the snow sweeper of 10 m/s, R 1 =0.25 m, α=5° and c=3 the Reynolds number of the radial case equals 2.4 and of the axial case 23 . Therefore the Reynolds number for radial flow is laminar, while the Reynolds number for axial flow is in the transition regime. This implies the calculated pressure drop in the axial case must be corrected with an extra diffusion term, making the pressure drop even higher. It must be stated the required power for the radial case is in the situation when the casing does not resist the flow, i.e. when there is no casing. In reality the required power will be slightly higher than the dotted lines of FIG. 15 . It can be concluded the perforation of the casing is a beneficial design aspect of the compression module. As discussed above the deformation of snow in the snow sweeper will occur through brittle deformation. Below is the discussion to determine the power needed to compress the snow towards the critical density. FIG. 14 shows the age of snow influence the compressive strength by a factor ten. At small values of α the wall compresses the snow and at large values of α the screw compresses the snow. The boundary for small values of α is taken as the corner where the pressure in z-direction is 10% of the pressure in r-direction. This corner equals arctan(0.1)=5.7°. The compressive stress in r-direction is shown in FIG. 16 . The principal stresses are build up in the same manner as in FIG. 12 . The compressive stress in r-direction results in two other stresses in z-direction and t-direction, indicated in FIG. 16 . The pressure delivered by the screw in z-direction and t-direction both need to be bigger than the principal stresses decomposed in z-direction and t-direction. The principal stresses in 2 and 3 direction of FIG. 12 are given by equation (4). Since φ is small, cos(φ)≈1. This means σ 3 ≈σ t and σ 2 ≈σ z . The minimal component σ min of the pressure by the screw on the snow determines the size of the pressure of the screw σ screw , indicated in FIG. 17 . Conventional conveyor screws have a pitch s, which is equal to the inner diameter (D inner ). This means the angle θ in FIG. 17 equals arctan(0.5)=27° and the minimal component of σ screw is in t-direction: σ min =sin(270)σ screw . The required power to compress the snow under the previous assumptions and method is given in FIG. 18 for the same initial conditions above (R 1 =0.25 m, R axis =0.10 m and σ 0 =100 kg/m 3 ). Dry friction occurs when two surfaces experience a relative lateral motion with respect to each other. The dry friction can be divided in two regimes. Static friction refers to surfaces not in motion and dynamic friction refers to surfaces in motion. In the compression module the snow experience a relative motion with respect to the casing, leading to dynamic friction. The size of the friction is related to the material properties of the two surfaces and the pressure normal to the wall. p f =μ d p ⊥   (13) where p f equals the friction pressure at the wall, μ d the dynamic friction coefficient and p ⊥ the normal pressure acting on the wall. For the compressing part of the conveyor screw p ⊥ is given in equation (14) p ⊥ =cos(α) p i   (14) where α is defined in equation (15) and p i is the pressure at position i for 0≦i≦L α = a ⁢ ⁢ tan ⁡ ( R 1 - R 2 L ) ( 15 ) where R 1 , R 2 and L are defined in FIG. 9A . In order to minimize friction a material of the casing must be chosen with a minimal friction coefficient with respect to snow. The friction coefficient is also an indication of the adhesion. It therefore depends on parameters like the temperature, grain shape, grain size and the liquid water content. A hydrophobic material, like Teflon, would be the material of choice. FIG. 19 shows the temperature dependency of adhesion. At temperatures above 0° C. a full water lubrication layer is present on the inner surface of the casing and at 0° C. the layer is incomplete. The friction in the range of 0° C. is dominated by the viscous behavior of the film layer. Since the casing is made of Teflon the bonding between the water film layer and the casing is low. At lower temperatures the liquid water content diminishes and the friction is dominated by plastic deformation of snow crystals. The snow sweeper must be capable to operate in the Netherlands and in the Nordic countries where temperatures of −35° C. are normal. The power needed to overcome friction for the same initial conditions as in the two previous sections is given in FIG. 20 . The power needed to overcome friction is transferred into heat. This generated heat flows into the casing, the air and snow. At entrance no film layer is present at −35° C. With a 100 nm layer of snow to be present on Teflon at 0° C. sufficient heat is supplied to create a full film layer at −35° C. Therefore the dynamic friction coefficient μ d =0.05. The results of the discussion can be added to obtain the total power to compress the snow, excluding drive train losses, as shown in FIG. 21 . The compression module decreases the volume flow, which leads to realistic values of the snow sweeper. The choice for a compression ratio is a trade off between power to compress the snow and dimensions of the snow sweeper. The breadth of a snow sweeper is about 20 m, which means 40 compression modules are required for one snow sweeper. A power of 10 kW per compression modules means a total power of 400 kW to compress the snow for one snow sweeper at a speed of 10 m/s. The geometry is chosen to be the following: α=5° and c= 3 At this geometry the required power is 3.3≦P≦19.5 kW per compression module and a total power of 132≦P≦780 kW. An exemplary snow removal system is provided. The test lower limit condition is a few centimeters slush and the upper limit is a lot of dry snow. The example was conducted in Raasdorf in the east of Vienna, Austria. Both the upper and lower limit snow conditions were experienced in Raasdorf. In the example, the compressions module was suspended with a category 2 front top hitch on a Massey Ferguson 7475 tractor from 2005. The forward velocity, hydraulic oil flow rate and the height of the compression module were operated. Provided is a working example of the compressive module. The boundary conditions for the model verification are: The mass flow at the inlet equals the mass flow at the outlet. The mass flow of the air leaving the compression module through the air holes is neglected, since the density of snow is a hundredfold of the air density. It is shown that snow is incapable of penetrating the air holes. {dot over (m)} inlet ={dot over (m)} outlet   (16) The fill factor is 100%, i.e. the start of the compression pipe is completely filled with snow. This boundary condition implies a relationship between the angular velocity of the screw and the forward velocity of the tractor. The relationship is based on the conservation of mass between the snow taken by the prototype and the casing inlet. The resulting relation between the tractor velocity and the angular screw velocity is given in equation (17). υ tractor = sc 1 2 ⁢ bh ⁢ ( R 0 2 - R axis 2 ) ⁢ ω ( 17 )  Where ν tractor is the tractor forward velocity, s=0.5 m and is the pitch of the screw, c 1 ≈1.5 and is the compression factor due to plowing, b=0.5 m and is the width of the compression module, h is the snow height, R 0 =0.25 m and is the initial inner radius of the conus, R axis =0.045 m and is the radius of the axis of the screw and ω is the angular velocity of the screw. The processed snow was untouched, i.e. uncompressed. This snow is denoted as fresh snow. When the boundary conditions are fulfilled the model will be tested for two different situations. Afterwards the holes were covered. The fraction of the required power for the pressure drop through air flow is minimal according the model. A significant power increase is expected in the second situation. The size of the tarmac site in this example was 200 by 40 meters. The width of the tractor is 2.67 meters, providing the number of passes per snowfall of about ten. Each pass represents a traveled distance by the tractor of 200 meters. The Parker Torqmotor TE130 was driven by the load sensing system of the Massey Ferguson 7475 tractor. The hydraulic diagram of the motor and sensors is given in FIG. 22 . First the oil from the tractor flows through the flow meter and then through the motor back to the tractor. At the inlet and outlet of the motor Parker SCPT sensors are located. These sensors can measure both pressure and temperature of the oil. The measured pressure drop is only over the motor of the screw, since the sensors are located at inlet and outlet of the motor. The hydraulic flow turbine meter is a Parker SCFT-150-02-02 with a maximum pressure of 420 bar and a maximum flow of 150 L/min. The measurement principle of the flow meter is illustrated in FIG. 23 . A part of the fluid energy is converted in rotational energy of the rotor. A pulse meter counts the rotor blades, which results in a signal containing the number of revolutions per time unit of the rotor. This signal is correlated to the volume flow. The hydraulic temperature and pressure meter is a Parker SCPT-400-02-02 with a maximum pressure of 400 bar and a temperature range from −25° C. to 105° C. The measurement of a pass of a compression module over 2 centimeters slush was executed at Jan. 8, 2013. Some accumulated snow at the front of the pass fell back, which explains the remainders on the snow-free pass of the compression module. The tractor velocity was 25 km/h. And the flow was set at 20 L/min during this experiment. The measurement of a pass of the compression module over 7 centimeters of wet snow was executed at Jan. 14, 2013. The ground temperature was sufficient in order for direct snow accumulation on the ground to occur. The ambient temperature was −1° C. Through these conditions the resulting snow can be denoted as wet snow. The fluid layer around each snow crystal allows a strong bonding between them in comparison to dry snow where a fluid layer does not exist. In this example, the density of the snow on the asphalt was calculated by dividing the measured mass through the measured volume. The mass was determined with a scale at an accuracy of 0.5 gram. The surface area was identical to the inner surface area of a pipe and the height was measured with a rod. A sample of compressed snow has a density of about 300 kg/m 3 . The measurement of a pass of the compression module over 30 centimeters dry snow was executed at Jan. 17, 2013. The ground temperature was sufficient in order for direct snow accumulation at the ground to occur. The ambient temperature was −2° C. and increased during the day to −0.5° C. It was difficult to make a snowball, where only through the application of a relative large force the snow was cohesive enough to maintain its spherical shape. The compression module was passed across the asphalt with a velocity of 25 km/h. As shown, the snow stream from the outlet is unaltered by the outlet design, since no snow eddies are present. The snow fell back on the cleared asphalt. The flow rate was set at 32 L/min, which is the prescribed flow rate at h=30 cm and ν tractor =25 km/h. FIG. 24 shows a schematic drawing of a snow removal system, according to one embodiment of the invention, where the invention includes a snow removal system, a compression module having a tubular casing with a snow inlet and a snow outlet, where the snow outlet includes a converging or decreasing cross-sectional surface area tubular shape, where the tubular casing is perforated with air holes, a road contacting device, for example a snow plow, a conveyor screw with a constant or decreasing pitch that rotates on an axis that is disposed concentric to the tubular casing, where the conveyor screw spans from the snow inlet to the snow outlet, where the conveyor screw is powered to move snow from the snow inlet to the snow outlet and compacts the snow to a compressed state by the converging tubular shape, where the compressed snow is output from the snow outlet, and a snow container that receives the compressed snow output from the snow outlet, where the snow container can be configured to store or exert the compressed snow. In one aspect, the snow container is a dumping container. In another aspect the container is a snow cube exerting container. FIGS. 25A-25C show different embodiments of the compression module having a converging casing and constant pitch screw, straight casing and diverging shaft of the screw, and straight casing and decreasing screw pitch, respectively, where it is understood that any of the screw profiles may be hollow with air holes and any of the casing profiles may have air holes, according to different embodiments of the invention. The present invention has now been described in accordance with several exemplary embodiments, which are intended to be illustrative in all aspects, rather than restrictive. Thus, the present invention is capable of many variations in detailed implementation, which may be derived from the description contained herein by a person of ordinary skill in the art. All such variations are considered to be within the scope and spirit of the present invention as defined by the following claims and their legal equivalents.
A snow removal system is provided that includes a compression module having a tubular casing with an inlet, and an outlet having a converging cross-sectional surface area shape and air-hole perforations, a conveyor screw concentric to the casing spanning from the inlet to the outlet is powered to move and compact the snow at the outlet, a conveyor belt moves the output snow away from the compression module at a velocity v 1 , a moveable truss houses the conveyor belt and supports the compression module, the device contacts a snow-covered surface and the truss moves at a velocity v 2 perpendicular to the snowplow, where v 1 is great enough to move the snow from the compression module when the truss moves at a velocity v 2, the conveyor screw turns at a rate that to incorporate V 1 and v 2 to ensure the conveyor belt capacity is not exceeded.
4
FIELD OF THE INVENTION [0001] The present invention in general, relates to an apparatus for installing and protecting a cable under sea and to the methodology for doing so. [0002] Particularly, the present invention relates to a technology for installation and protecting a cable in subsea conditions running from an offshore bottom-fixed structure to other offshore or onshore structures. [0003] More particularly, the present invention relates to an apparatus according to the preamble of claim 1 and to a method according to the preamble of claim 12 . TECHNICAL BACKGROUND OF THE INVENTION [0004] In offshore operations such as oil and gas explorations and productions, installing and protecting cables running from an offshore structure resting on seabed, to other offshore and onshore structures is quite common. [0005] Such an offshore structure may be for example a platform/foundation resting on the seabed for supporting a wind turbine. There can be other examples as known to persons skilled in the art all of which fall within the ambit of the present invention, such as a fixed offshore oil or gas facility or an offshore transformer station. It is also known that for the sake of stability, such foundations are frequently provided with scour protection around the base. [0006] Offshore cables are typically heavy, thick and do not bend in sharp curves. They are also quite expensive, sensitive and costly to repair. [0007] Close to the offshore foundation, the cable needs to be protected from for instance excessive movement, over-bending and damage from dropped objects. Excessive movement is most likely to occur during the installation phase, while the risk for over-bending is often a product of under-scouring of the cable and ensuing free span. [0008] Dropped objects are primarily rocks dumped around the foundation to prevent scouring of the foundation, but also include non-intentionally dropped objects throughout the operational life of the cable. Hence, installation and protection of the cable between the outer edge of the scour protection and point of its entry into the foundation is of vital importance. The cables extend from the seabed to the foundation on the seabed and then to the structure supported by the foundation. [0009] The current state of the art consists of various forms of sheathing or pipes that are installed around the cable, usually at the time of cable installation. The cable is usually installed significantly later than the foundation and its scour protection. Ideally, the cable should go under the scour protection, in which case a costly operation is needed to remove the scour protection to allow the cable and then replace the scour protection to ensure stability of the foundation. [0010] The cable conduits inside the offshore structure will typically be curved (this is always the case for offshore wind foundations). Telescopic arrangements are conventionally thought of as comprising two straight elements, which fit into each other and allow the same shape (straight tube) to be maintained throughout the adjustment of length. Thus, traditional telescopic arrangement is not possible here. A key point of the invention is that the inner tube is elastic, which allows it to assume the shape of the outer tube in retracted position and to return to an essentially straight shape after extension. [0011] Installation and protection of subsea cables extending from, on or into the seabed, to the wind turbine or other structures supported by a foundation, with the help of tubular structures such as J-tubes, are known. Apart from the problem stated in the preceding paragraph, the requirement for divers became almost indispensable for installing such cables into the J-tubes. Even using telescopic J-tubes did not help because divers were required to lock the J-tube in place after installation. [0012] U.S. Pat. No. 7,438,502 teaches a telescopic under-water guiding assembly for subsea elements such as cables. It teaches a telescopic assembly of an outer receiver pipe to which is slidably engaged an inner extension pipe, which can undergo extraction and retraction. A cone end is secured to the inner extension pipe. The latter is locked in a fixed position with binding blocks with set screws. [0013] The above patent does away with the requirement for deploying divers; however it does not teach how the requirement for removal of the scour protection, during its installation can be dispensed with. Further, it does not specifically teach that the protective apparatus can be installed along with the foundation. Furthermore, the arrangement is fairly complicated. These aspects are true for other prior art teachings as well. [0014] US 2010/0196100 shows a tubing arrangement for an offshore facility where a first tube section comprising a curved part is affixed to the outside of an offshore structure and extends from above the sea surface to near the seabed. A second tube part is hinged to the lower end of the first tube part. A third flexible tube part is attached to the outer end of the second tube part. During installation of the structure, the third flexible tube part is coiled up and the second part is pivoted upwardly. When the structure has been installed, the second part is pivoted downward towards the seabed and the flexible tube part is coiled out. The end result is a conduit for a cable or the like to be installed, which extends vertically along the structure and curves into a direction substantially parallel with the seabed. [0015] Although, this arrangement can provide for post-installation of a cable after scour protection has been deployed, it has some major disadvantages. The most important disadvantage is that the tubing is arranged so that it is highly subject to damage during installation. This is especially true for the second and third parts, which extends substantially outward from the structure during installation. [0016] U.S. Pat. No. 7,438,502 shows a straight telescopic tube that is adapted to extend from the deck of a platform to the seabed. The tube can be extended to adjust the length of the tube. [0017] The tube of U.S. Pat. No. 7,438,502 is not suitable for conducting a cable or the like below a scour protection. The tube will form a straight line set at an angle from the deck to the seabed and at best extend above any scour protection. Hence, it permanently installed, the tube will be subject to potential damage from any ships that come too close to the structure. It will also be subject to damage from waves and currents. [0018] U.S. Pat. No. 3,724,224 shows a J-tube that may be pre-installed within the seabed structure. A pipe can be pulled through the J-tube. This pipe is fed from the platform deck after the installation and is pulled along the seabed to another platform. The pipe is exposed between the first and the second platforms. Hence, the pipe has to be installed before any scour protection is deployed around the first platform. If the pipe has to be replaced, the scour protection covering the pipe has to be removed. [0019] U.S. Pat. No. 4,523,877 shows an arrangement similar to U.S. Pat. No. 3,724,224. Here a J-tube is preinstalled within a structure. After the installation of the structure, a riser is fed through the J-tube. The part of the riser that extends through any scour protection is exposed, so that it is not possible to deploy scour protection before the riser is installed or remove the riser without first removing the scour protection. [0020] FR 2378227 shows a protective cover comprising a plurality of shields that can be stacked inside each other during installation. After the installation, the shields are deployed in an overlapping line to form a protective cover for a pipe or cable. However, this system of shields is complicated to deploy and necessitates the use of a diver. Moreover, it is not possible to feed a pipe or cable from a position above the sea surface to a position outside the cover. [0021] Hence, there has been a need for a simple and efficient apparatus to act as a conduit for installation and protection of subsea cables, which dispenses of the requirement for removal of the scour protection of the foundation, during its installation. [0022] There is also a need for a technology that provides such an apparatus, which can be installed along with the foundation, prior to providing the scour protection. This is to ensure that the apparatus extends for a pre-determined length along the seabed, through the zone in which scour protection is to be applied later, so that the cable can be installed through the scour protection since applied, without the need for removing it. [0023] The present invention meets the above mentioned needs and other associated needs by providing an apparatus which has a first tubular member arranged to move telescopically with respect to the second tubular member, such that both can be installed together with the foundation, through the zone of possible scour protection, before it is applied. OBJECTS OF THE INVENTION [0024] It is the prime object of the present invention to provide an apparatus which acts as a continuous conduit for installation and protection of subsea cables, which has a simple construction and does away with the requirement for removal of scour protection of the foundation during installation of the cables. [0025] It is another object of the present invention to provide a method for installation and protection of subsea cables, which works in a very simple and efficient manner. [0026] It is a further object of the present invention to provide an apparatus for installation and protection of subsea cables which can be installed along with the foundation prior to the application of scour protection, so that the apparatus extends to a predetermined length and forms a continuous conduit from the top to the seabed, through the scour protection, once applied. [0027] All through the specification including the claims, the words “vessels”, “platform/foundation”, “J-tube”, “protective tube”, “cable”, “bell mouth”, “scour protection”, “cable pull-in wire” are to be interpreted in the broadest sense of the respective terms and includes all similar items in the field known by other terms, as may be clear to persons skilled in the art. Restriction/limitation, if any, referred to in the specification, is solely by way of example and understanding the present invention. Further, it is hereby clarified that the term “tubes” should include “pipes”, “tubular members” and other similar structures as applicable. SUMMARY OF THE INVENTION [0028] The above mentioned objects are achieved by an apparatus for installation and protection of subsea cables from a seabed unit, comprising at least one first tubular member and at least one second tubular member, said first tubular member is arranged telescopically on the outside or the inside of said second tubular member, both tubular members being pre-installed within the seabed unit and allowing passage of at least one cable there-through, said first tubular member being adapted to be extracted outwardly from the second tubular member, while said second tubular member remain essentially stationary with respect to said seabed unit, to a position essentially flat on the seabed, in order to extend through a desired zone for scour protection. [0029] The invention also relates to a method for installing a subsea cable from a seabed unit, said method comprises the following steps: [0030] a) pre-installing at least one second tubular member and at least one first tubular member within the seabed unit so that the first tubular member is arranged telescopically with the second tubular member; [0031] b) installing the unit in the seabed while retaining the first tubular member (1) relative to the second tubular member; [0032] c) releasing the first tubular member from the second tubular member; [0033] d) pulling the first tubular member outwardly from the second tubular member, so that the first tubular member extends outwardly essentially along the seabed to a location outside a desired scour protection zone; [0034] e) pre-installing or passing a cable pull-in line through the second tubular member and the first tubular member, so that the pull-in line with a first end extends out from the outer end of the first tubular member, and with a second end extends out from an end opposite of the first tubular member of said second tubular member; [0035] f) attaching a cable to be installed to the first end of the pull-in line; [0036] g) pulling the line pull-in line with the cable trailing; [0037] h) before or after steps f) and g), applying scour protection around the seabed unit and on a part of the first tubular member. [0038] Further favourable features are recited in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS [0039] Having described the main features of the invention above, a more detailed and non-limiting description of a n exemplary embodiment will be given in the following with reference to the drawings. DETAILED DESCRIPTION OF THE INVENTION [0040] FIG. 1 shows the general arrangement of a foundation in a bottom-fixed condition together with the J-tube and the protective pipe, according to a preferred embodiment of the present invention, with the J-tube yet to be installed on seabed. [0041] FIGS. 2 a , 2 b , 2 c , 2 d show in detail the structure and working of a preferred embodiment of the stopping means according to the present invention, where FIG. 2 a shows the stopping means out of engagement with the pipe in a elevation view, FIG. 2 b shows the situation in FIG. 2 a in a plan view, FIG. 2 c shows the stopping means in engagement with the pipe in a elevation view, FIG. 2 d shows the situation in FIG. 2 c in a plan view. [0042] FIG. 3 shows a detail of the outer end of the pipe and the J-tube with another preferred embodiment of the stopping means of the present invention. [0043] FIGS. 4 a and 4 b show detail views of the clamp shown in FIG. 3 . [0044] FIG. 5 a is a view of the detail arrangement of the protective pipe according to the present invention, prior to its pull-out. [0045] FIG. 5 b is a view of the details of a hinged pull-out bar according to FIG. 5 a. [0046] FIG. 5 c is a view of the details of a friction clamp shown in FIG. 5 a. [0047] FIG. 6 is a view which explains the method of pulling out the HDPE/protective pipe from the J-tube. [0048] FIG. 7 is a view of a stage when the HDPE pipe has been pulled out of J-tube, awaiting dumping of filter bags. [0049] FIG. 8 is a view which shows filter bags that have been placed over the HDPE pipe after extraction and it is ready for the scour protection system to be installed. [0050] FIG. 9 is view of a stage when scour protection has been completed and the cable is to be installed. DETAILED DESCRIPTION OF THE INVENTION [0051] The following describes a preferred embodiment of the present invention which is purely exemplary for the sake of understanding the invention and non-limiting to the protective scope. [0052] In all the figures, like reference numerals represent like features. Further, when in the following it is referred to “top”, “bottom”, “upward”, “downward”, “above” or “below” and similar terms, this is strictly referring to an orientation with reference to the seabed, where the seabed is horizontal and at the bottom. [0053] It should also be understood that the orientation of the various components may be otherwise than shown in the drawings, without deviating from the principle of the invention. [0054] Additionally, the present invention is explained with reference to a J-tube, within which there is a protective tube, which is telescopically movable with respect to the J-tube. This protective tube is essentially an HDPE tube, but can consist of other suitable materials. It should be understood, that the present invention embraces all such arrangements of two or more tubular members which are capable of being arranged telescopically for forming a continuous conduit for a subsea cable to pass through. [0055] The cables which are proposed to be installed and protected by the apparatus of the present invention, essentially extend from other offshore or on-shore structure(s), on or embedded into the seabed near a foundation resting on the seabed, then into the foundation and up to the structure supported by the foundation. [0056] In most of the figures only one J-tube and one protective tube are shown for the sake of convenience. There can be a plurality of such J-tubes and protective tubes within the foundation according to the present invention. This is true for the various other associated components described. The J-tube and the protective tube may each be a single tube or each may be a number of tubes, attached together to form a J-tube and a protective tube of the present invention. [0057] FIG. 1 is a view of the general arrangement of major components of the apparatus when the protective pipe 1 has not been extracted out to the seabed 5 from the J-tube 2 , but still resides within the outer J-tube 2 . It shows the foundation 3 , which in this example is a gravity based structure (GBS) resting on the seabed 5 . The foundation 3 supports a topside structure (not shown) at its top end 4 . The topside structure may be a windmill extending upwards from the water surface 31 . [0058] Within the foundation 3 is already pre-installed the apparatus of the present invention, which is now to be described. In this example it is a J-tube 2 , preferably made of a non-flexible material, such as steel, glass fibre reinforced plastic (GRP), carbon fibre reinforced resin or other suitable material, extending downwards from the top end 4 . The J-tube has a conical portion 2 b and a curved portion 2 a , which has a greater diameter than an upper straight portion 2 c . The protective pipe 1 is accommodated within the curved portion 2 a of the J-tube 2 , between the end 7 of the J-tube and its conical portion 2 b . The protective pipe 1 is slidable with respect to the J-tube 2 . Thus, it is a telescopic assembly and the protective pipe 1 can be pulled out of the J-tube 2 beyond the end portion 7 , by a horizontal pulling force. [0059] The protective pipe 1 is generally made of a somewhat flexible material like High Density Polyethylene (HDPE) which allows it to be inserted into and bent according to the shape of the J-tube 2 and will below sometimes be referred to as HDPE pipe 1 . Other materials, such as carbon fibre reinforced resins may also be used. [0060] The FIG. 1 also shows the end portion (bell mouth 30 ) of the retracted HDPE pipe 1 , which is seen coinciding with the end portion 7 of the J-tube 2 . A stopping means 6 (explained in detail below) can also be seen which prevents the HDPE pipe from being inadvertently extracted, or retracted once it is installed on the seabed 5 . This stopping means 6 is provided in close proximity to the end portion 7 . The conical section 2 b forms a transition between the curved portion 2 a and the straight portion 2 c , with a smaller diameter than the curved portion 2 a , of the J-tube 2 . [0061] FIGS. 2 a , 2 b , 2 c and 2 d are detailed views of the end portion 7 of the J-tube 2 , showing a preferred embodiment of the stopping means 6 . The stopping means 6 prevents extraction or retraction of the protective tube 1 beyond a certain pre-defined limit. It comprises a plate 8 a provided near said point of exit, which can slide along vertical stands 8 b for engagement with complementary grooves 9 in the outer surface of the protective tube. The grooves 9 are provided at specific points on the protective pipe 1 where it is desired to retain it with respect to the J-tube 2 . When the pipe 1 has been pulled out the desired length, the sliding plate 8 a , whose rounded profile matches with the diameter of the groove 9 , can be inserted into the appropriate groove 9 and lock the movement of the pipe 1 . [0062] The sliding plate 8 may fall into the groove 9 by gravity or by spring force or may be operated manually by an ROV or an actuator (not shown). With this mechanism, the pipe 1 is locked in position with the J-tube 2 and can neither move forward or backward. This would be particularly clear from the front views 2 a and 2 c which shows two consecutive stages, in the first stage the sliding plate 8 is approaching the grooves 9 but is yet to become engaged. In FIG. 2 c the two are in engagement with each other. This would be clear from FIG. 2 d as well, of which FIG. 2 c is a front view. It shows clearly the engagement between the grooves 9 and the sliding plate 8 . Disposition of grooves 9 along various lengths of the pipe 1 provides the option to selectively predetermine the length of the pipe 1 that will be extracted out of the J-tube. In a separate detail view in FIG. 2 c , the plate 8 a is shown separated from the rest of the stopping mechanism. [0063] FIG. 3 shows another embodiment of the stopping means 6 . This comprises a restraining wire 10 is attached to a ring 35 attached to the protective pipe 1 . The ring is in turn connected to a cover 18 by a connection wire 36 . The cover 18 prevents entry of unwanted material like soil or small rocks into the pipe 1 during installation. The restraining wire 10 is at its opposite end secured to a pad eye 19 fixed to the foundation 3 . The restraining wire 10 restrains the protective pipe 1 from extracting out of the J-tube 2 . A safety wire 12 is also connected between the ring 36 and the pad eye 19 . The safety wire has a length corresponding with the desired extraction length of the pipe 1 . [0064] FIG. 3 also shows a clamp 11 near the protective pipe 1 for clamping the same in order to prevent the pipe from retracting into the J-tube when it has been extracted to the desired length. FIG. 4 a is an enlarged view of the clamp 11 which is of the hinged type, having a hinge 16 . FIG. 4 b is an enlarged view of the clamp 11 in operation which shows a T-bar 17 a for engagement by an ROV, a right hand thread bar 17 b , a stopper plate 17 c welded to the thread bar 17 b , a plate 17 d with an oblong hole (not shown) to allow the thread bar to pass through, and a left hand thread bar 17 e. [0065] Referring back to FIG. 3 , the cover 18 is equipped with a handle 14 for attachment by a pull-out line (to be explained later) for pulling out the protective pipe 1 . FIG. 3 also shows a pull-in line 13 , which is used to pull in a cable inside the fully extracted protective pipe 1 , as will be explained later, and a monkey fist ROV grab 15 attached to the outer end of the pull in line 13 . [0066] FIGS. 5 a and 5 b show another alternative embodiment of the stopping means as well as a different embodiment of the means for extracting the pipe 1 . Here a friction clamp 20 is preinstalled at the outer end 7 of the J-tube and adapted to clamp the pipe 1 , to ensure that after the pipe 1 has been extracted to a desired length, it does not retract back inside J-tube, particularly when the cable 29 (shown in FIG. 9 ) is pulled in through the protective pipe 1 . The clamp 20 is explained in detail in FIG. 5 c. [0067] FIGS. 5 a and 5 b also shows a hinged pull-out bar 21 that is attached to the outer end of the pipe 1 and is to be used for pulling out pipe 1 . The hinged pull-out bar 11 is attached to the pipe 1 in close proximity to the end portion 7 , and just behind the bell mouth 30 . It also shows the cable pull-in wire 13 , which in this embodiment is attached to the hinged pull-out bar 21 by a sacrificial wire sling 23 . The overall length of the pull-in wire 13 , which is, e.g., 20 to 25 meters, may be arranged on a bracket reel (not shown) located at the upper end of the J-tube. [0068] A restraining wire sling 10 is connected to the end portion 7 of the protective pipe 1 to prevent the pipe 1 it from accidentally sliding out during transport and installation of the structure 3 . A safety wire 12 is secured to the pad eye 19 fixed to the foundation 3 and is also connected to the pull-out bar 21 . The safety wire has a length corresponding with the desired extraction length of the pipe 1 . Once fully extracted, through the possible zone of scouring for the foundation 3 , the protective pipe 1 cannot retract into the J-tube 2 as it is arrested by the friction clamp 20 . [0069] FIG. 5 c is a close view of the friction clamp 20 that is used to arrest the motion of the pipe 1 after it has been pulled out. This is actually a tong like arrangement with friction linings on the inner faces. The two arms 20 a and 20 b are hinged at one end 20 c and at the other end threaded bar and nut arrangement 20 d are provided for closing the two arms 20 a , 20 b . This threaded bar and nut arrangement 20 d can be operated by an ROV. On activation, the device firmly clamps the pipe 1 , without damaging it. [0070] FIG. 6 shows an exemplary arrangement to facilitate the pull-out of the protective pipe 1 from the J-tube 2 . It shows two sets of J-tubes 2 and protective pipe 1 within the foundation. In practice, there can be several J-pipes, as explained above. A sling wire 24 is attached to the hinged pull-out bar 21 (shown in FIGS. 5 a and 5 b ) or to the handle 14 of the cover 18 , which is fixed to the pipe 1 near the outer end thereof, and is passed through a pulley held near the seabed with a clump weight 25 . [0071] The pulling wire 24 is attached to a constant tension winch 26 placed on a vessel 27 on the water surface 31 . The pulling wire 24 can thus provide a substantially horizontal pull to the hinged bar 21 and thus to the pipe 1 for smooth extraction from the J-tube 2 . [0072] FIG. 7 is a view of a stage when the protective pipe 1 has been pulled out of the J-tube 2 awaiting placement of sand bags, filter bags or other types of relatively soft material that is able to protect the pipe 1 from the rocks of the scour protection. [0073] FIG. 8 is a view of the stage subsequent to what is shown in FIG. 7 . Filter bags 27 have been placed over the protective pipe 1 and is now awaiting application of scour protection. It also shows the bell opening 30 of the fully extracted protective pipe 1 which is outside the possible zone of scour protection. Now scour protection for the foundation 3 is next to be applied. [0074] FIG. 9 is a view of a stage when scour protection 28 has been applied and the cable 29 is about to be pulled into the bell mouth 30 with the help of the cable pull-in wire 13 (shown in FIGS. 3 and 5 a ). [0075] The above figures are again referred to now for the purpose of explaining the operation of installation of the apparatus and the cables so that the functioning of each component, as described hereinbefore is understood. [0076] At the first stage on-shore preparation of foundation 3 for offshore installation is done. First, the protective pipe 1 is inserted into the J-tube 2 and placed within the foundation 3 . In this configuration, the protective device 1 is itself protected and does not get in the way of marine operations. This arrangement is shown in FIG. 1 . The components shown in FIG. 1 have been explained in detail before with reference to FIG. 1 and are not repeated. [0077] The foundation 3 with the J-tube 2 and protective pipe 1 so installed are now towed to the offshore location. The sacrificial hold back sling 10 , connected to the end portion of the protective pipe 1 shown in FIG. 3 or 5 a , ensures that the protective pipe 1 does not accidentally slide out of the J-tube 2 during towing. The foundation 3 is thereafter suitably installed on the seabed 5 . The installation of the foundation will not be described in detail here, as this procedure is known to persons skilled in the art. [0078] After installation of the foundation 3 on the seabed 5 , the hold back sling 10 is cut (preferably by an ROV). Now one end of the sling wire 24 is attached to the hinged pull-out bar 21 or the handle 14 . The bar 21 or the handle 14 is fixed to the pipe 1 (as shown in FIGS. 3 and 5 a ) close to the end thereof. The other end of the sling wire 24 is passed through a pulley held near the seabed with a clump weight 25 and attached to a constant tension winch 26 placed on a vessel 27 on the water surface 31 . This provides a substantially horizontal pull to the pipe 1 , so that the pipe 1 is smoothly extracted from J-tube 2 . [0079] As shown in FIG. 7 , the pipe 1 is pulled out in the direction of the arrowhead along the seabed 5 . FIG. 8 shows the bell mouth 30 of the fully extracted protective pipe 1 . The bell mouth 30 is now outside the application zone of scour protection. Further, it would be clear from FIG. 7 and also from FIGS. 8 and 9 , that the J-tube 2 and the fully extracted protective pipe 1 form a continuous conduit for cables from the top portion 4 of the foundation 3 to the seabed, through the zone of scour protection. For that purpose, it is vital that the length of extraction of the protective pipe 1 is predetermined accurately. [0080] On reaching the desired length of pull-out, the protective pipe 1 is locked in position by suitable stopping means 6 , as explained with reference to FIGS. 2 a , 2 b , 2 c , 2 d , 5 a and 5 c . This stopping means 6 ensures that once the maximum length of extraction of the protective pipe 1 is reached, it neither retracts back, say during cable pull-in through the extracted protective pipe 1 and J-tube 2 , nor accidentally slides further out of the J-tube. [0081] It needs to be explained further with reference to the pull-out of the protective pipe 1 as explained in the preceding paragraphs, that while the pipe 1 is pulled beyond the intended scour protection area on the seabed 5 , it simultaneously pulls the cable pull-in wire 13 along with it. The cable pull-in wire 13 is attached to the hinged pull-out bar 21 with a sacrificial sling 23 as shown in FIG. 5 a or is prevented to escape into the pipe 1 by the cover 18 , as shown in FIG. 3 . The cable pull-in wire 13 thereby passes through the J-tube 2 and protective pipe 1 . Actually prior to pull-out of the pipe 1 , this wire 13 is made to pass through the J-tube 2 and the pipe 1 such that one end of this wire extends out of the outer end of the pipe 1 while the other end extends out of the J-tube at its upper end. [0082] After the scour protection 28 is applied, the cable 29 , which may already be placed near the bell mouth 30 , may be inserted into the bell mouth 30 . For that purpose, the pull-in wire 13 is attached to the cable 29 and pulled in through the bell mouth 30 through the extracted protective pipe 1 and up the J-tube 2 , pulling the cable 29 with it. [0083] Thus cable installation is achieved after the scour protection has been applied. The need for removal of scour protection is effectively eliminated. This is possible because the protective tube can be pulled out of the J-tube to a pre-determined length. This length is so adapted that the end with the bell mouth 30 of the extracted pipe 1 is beyond the scour protection 28 . At this length the pipe 1 will be locked relative to the J-tube. [0084] Thus it is always ensured that the pull-out of the pipe 1 is always unidirectional and maintains the desired, pre-calculated length. Further, as the HDPE pipe 1 is pre-installed in the J-tube 2 and both are installed on the seabed 5 along with the foundation 3 , the entire operation is very weather robust. [0085] The present invention has been described with reference to a preferred embodiment and some drawings for the sake of understanding only and it should be clear to persons skilled in the art that the present invention includes all legitimate modifications within the ambit of what has been described hereinbefore and claimed in the appended claims. [0086] As an alternative to the relatively flexible pipe 1 , the pipe may also be stiff but curved to correspond with the curvature of the curved portion 2 a of the J-tube 2 . This means that the pipe 1 will curve upwards when it has been extracted. However, after full extraction, the pipe may be rotated through 90° so as to lay flat on the seabed. This will require a somewhat longer pipe 1 , as the pipe will extend in a curve through the scour protection zone. [0087] It is also conceivable to have the pipe 1 telescopically received on the outside of the J-tube 2 Instead of on the inside. [0088] It is also evident that other means for preventing the pipe 1 from sliding inadvertently out of or into the J-tube 2 may be used. Instead of ROV operated means, remotely operated actuators may be attached to the foundation, pipe 1 and J-tube 2 .
An apparatus for installation and protection of subsea cables comprises at least a first tubular member ( 1 ) and at least a second tubular member ( 2 ). Both these are arranged to be installed subsea with a subsea foundation ( 3 ). This allows passage of cable ( 29 ) through it. The first tubular member ( 1 ) is arranged telescopically within the second tubular member ( 2 ) so as to extract outwardly towards seabed ( 5 ) from an end portion ( 7 ), with respect to the second tubular member ( 2 ), only up to a prefixed length. This ensures that a continuous conduit for the cable is obtained through the scour protection of the foundation ( 3 ). The present invention also includes a methodology for installation of the apparatus and a method for installing a cable through the scour protection of the foundation, by using the apparatus.
4
BACKGROUND The invention relates to an arbitration circuit. More particularly, the invention relates to a preemptive round robin arbitration circuit. When an asset or resource, such as a personal computer data bus, needs to be used by multiple requesters, such as a modem, a hard disk and/or a software program, some kind of allocation scheme needs to be provided. Hence, if no single asset or resource is in an extreme hurry, a round robin scheme may be used where, on a given clock cycle, one device request line is polled to ascertain whether or not that requester or device has a need for the asset. If there is a request, the request is granted for an appropriate amount of time. After that request is removed or finished, the system proceeds to the next requester in line. If a device far down the line of requesters in the round robin circuit has a request even though no one else has a request between the present arbitration logic circuit and the one connected to a requester requiring access to the asset, the circuit may still require one or more clocks to get to the requester having a present need to acquire the use of the asset. Therefore, overhead for the conventional round robin circuit may take more than one cycle when the service is granted from one request to another request. Furthermore, the circuit may not allow an interactive request to break in during a granted batch request if both batch request and interactive request are asserted resulting in the response time to the interactive request to become intolerable. The interactive request is an asynchronous request typically containing control information, whereas the batch request is a synchronous request typically involving sequentially accessed data. In some cases, conventional resource allocation schemes use a priority interrupt technique where the requester with the most priority is always the next one to have access to the asset. However, with such a priority interrupt technique, a requester with low priority may have to wait an extremely long time before being granted access to an asset. SUMMARY In one aspect, a resource allocation arbitration system is disclosed. The system includes a plurality of storage devices, a plurality of indicators, and a plurality of mask bits. Each storage device stores requests for resources. Each indicator enables indication of a condition in which the request stored in each storage device is almost empty. Furthermore, the mask bits enable preemption of one request by another request. In another aspect, an arbitration method is described. The method includes storing requests for allocation of resources, indicating a condition in which the stored requests are almost empty, and arbitrating the allocation of resources by providing selection bits that operate in conjunction with the indicator to substantially reduce idle time between the requests. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments, but are for explanation and understanding only. FIG. 1 illustrates one embodiment of a modified round robin configuration. FIG. 2 is an interface timing diagram of one embodiment of a modified round robin sequence. DETAILED DESCRIPTION In recognition of the above-stated problems associated with conventional resource allocation schemes, embodiments for a modified round robin approach are described. This modified round robin approach provides equal access opportunity to all resources while enabling a substantial decrease in time to perform the round robin cycle. Consequently, for purposes of illustration and not for purposes of limitation, the exemplary embodiments are described in a manner consistent with such use, though clearly the invention is not so limited. A modified round robin configuration 100 according to an embodiment of the invention is illustrated in FIG. 1 . Each request, in the round robin configuration 100 , whether interactive or batch, is queued to a first-in first-out (FIFO) buffer. In the illustrated embodiment, there are N requests, some of which are interactive requests (x) and others are batch requests (N-x). As long as the FIFO buffer is not empty, information in the buffer may indicate a request. In the illustrated embodiment, to prevent the idle gap between granting of the next request and ending of the current request, each FIFO has an ALMOST-EMPTY flag to indicate that the FIFO buffer has only one item left in the request. Hence, when the ALMOST-EMPTY flag is on, granting of the request goes to the next available request in the round robin sequence by setting a grant selection register (GSR) for the next available request. Therefore, by granting the request one sequence in advance of the depletion of items in the current request FIFO buffer, the idle gap between requests may be prevented. Furthermore, this back-to-back granting-of-request mechanism requires substantially low overhead because an existing pointer for the FIFO buffer may be used as the ALMOST-EMPTY flag. In one embodiment, each of the ALMOST-EMPTY flags is coupled to a read/write pointer. The above-described improved granting sequence is implemented using logic gates J, K, and L to set a grant bit in the corresponding grant selection register (GSR). Thus, logic NAND gate J asserts its output (a logical 1) when either the ALMOST_EMPTY flag is not set or the current grant bit is not set. Logic AND gate K is asserted when the request is initiated and the mask bit of the corresponding mask register (MR) is set while logic gate J is asserted. Finally, logic AND gate L sets the grant bit of the corresponding grant selection register when the logic gate K is asserted but logic gates corresponding to other grant bits are not asserted. Further, as soon as the grant bit is set, the SET_MASK flag for the batch requests is de-asserted. FIG. 2 is an interface timing diagram of a modified round robin sequence according to an embodiment of the invention. The sequence has three resource allocation requests. The first two requests are batch requests A and B. The third request is an interactive request C having two items D and E. Signals GrantA and GrantB indicate that the service is granted to the batch request B right after the granted batch request A is completed. No idle gap is shown in the timing diagram. Referring to FIG. 1 , to allow the interactive requests to preempt the batch request, the mask bit of the currently granted batch request remains active until the request is emptied. Furthermore, the mask bit of the interactive request is implemented by permanently asserting the corresponding mask bit. Thus, the interactive request is made non-maskable. If an interactive request is made during the granted period of a batch request, the batch request is suspended until the interactive request is serviced. Once the interactive request has been serviced, the suspension of the batch request may be resumed. Therefore, the preemptive arbitration circuit not only generates a short response time but also allows the interrupted request to recover. The above-described preemptive arbitration sequence is implemented using logic gates X and Y, and the mask register (MR). For this sequence, the mask bits of the corresponding interactive requests of the mask register (MR) are set to one. The mask bits of the corresponding batch requests are controlled as follows. Logic AND gate X is asserted when the request is initiated and the mask bit of the corresponding mask register (MR) is set. Logic OR gate Y is asserted when logic gate X is asserted or when SET_MASK flag is asserted. Assertion of logic gate Y sets the corresponding mask bit of the mask register (MR) to one and allows the batch request to resume the interrupted sequence, or sets the corresponding mask bit of the MR to zero when service for the current request is done. The mask bit plus the grant priority order flows right to left with respect to FIG. 1 . GrantC signal (corresponding to the interactive request) in the interface timing diagram of FIG. 2 illustrates that the service is granted to interactive request C one cycle after item D in request C presented the request. When item D is removed, the suspended request B is resumed. When item E in request C is presented, the service is again granted to interactive request C. When item E is removed, the suspended request B is again resumed. There has been disclosed herein embodiments for a modified round robin configuration which includes an improved granting sequence and a preemptive arbitration scheme. The improved granting sequence enables short response time to requests by substantially reducing any idle time between requests. This sequence uses an existing pointer to provide an indication of an “almost empty” buffer. The preemptive arbitration scheme allows interactive requests to preempt the batch request. Furthermore, the scheme also enables the batch request to recover from the interruption. While specific embodiments of the invention have been illustrated and described, such descriptions have been for purposes of illustration only and not by way of limitation. Accordingly, throughout this detailed description, for the purposes of explanation, numerous specific details were set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the embodiments may be practiced without some of these specific details. For example, although the improved round robin configuration of FIG. 1 uses logic gates to perform the above-described sequences, other comparable circuits and/or elements that perform similar functions may be used. In other instances, well-known structures and functions were not described in elaborate detail in order to avoid obscuring the subject matter of the invention. Accordingly, the scope and spirit of the invention should be judged in terms of the claims which follow.
A resource allocation arbitration system. The system includes a plurality of storage devices, a plurality of indicators, and a plurality of mask bits. Each storage device stores requests for resources. Each indicator enables indication of a condition in which the request stored in each storage device is almost empty. Furthermore, the mask bits enable preemption of one request by another request.
6
BACKGROUND AND BRIEF SUMMARY OF THE INVENTION The United States Government has rights in this application and in the subject invention pursuant to contract Number EY-76-C-02-0016 with the U.S. Department of Energy. This invention relates to the production by the combustion of coal, of gas streams which are free of particles above a certain size. More particularly, it relates to the production of streams of coal combustion gases significantly free of particles larger than about 2 to 5 microns and which may be used to drive gas turbines. Open, combined cycle coal-fired turbine systems (i.e., systems where combustion gas streams are used to directly drive turbines) offer the potential for high thermal efficiency along with good control of air pollutants. A prime concern in this type of power plant is the particulate loading and amount of corrosion to which the turbine is subjected. Such is the case for various coal combustion schemes, including pulverized coal firing, cyclone furnaces, and pressurized fluidized beds. Blade erosion due to particulates or deposition and corrosion due to chemically reactive species present in the turbine inlet stream are reported to be critical problems facing this method of power generation. Turbine lifetime greatly influences the economic attractiveness of open-cycle coal-fired turbines. Clearly, if the particulate and ash fouling problems could be overcome without compromising power cycle performance coal-fired gas turbines would become more attractive. Removal of particulate matter from the turbine inlet stream by electrostatic precipitators or rotary flow cyclones has been investigated. Although both of these cleanup systems can operate at the high temperature necessary for good turbine efficiency, they do not appear suited to effective removal of particles smaller than 10μ. Cyclones modified for the removal of small particulates, such as that described in the application by Warren Winsche (Ser. No. 901,047), commonly owned, have been proposed; however, to the best of the applicants' knowledge, none have been demonstrated. Efficient removal of ash particles less than 10μ in diameter should greatly improve the practicality of coal-fired turbines. Bag filters have been proposed as a means of achieving the desired low particulate loadings. The mechanical and materials problems of operating a bag filter at high temperatures are very formidable, however, and would require an extensive development effort. In addition, the reliability of the filters must be extremely high. A partial failure of the filter systems could result in excessive turbine erosion. Continuous accurate monitoring of the combustion stream would be required to determine particulate loadings and size distributions. A radically different and novel approach would be to destroy, rather than remove, all particles above the size limit, approximately 2 to 5 microns, which can be accepted by the turbines without excessive corrosion. By destroy herein is meant to vaporize or fragment so that the resulting fragments are below the above described size limit. This approach is carried out by the apparatus of the subject invention which comprises coal combustion means for producing a particulate laden stream of coal combustion gases connected to a cavity through which the particulate laden gas stream flows, laser means for providing intense illumination of appropriate wave length whereby particles exposed to said illumination will be destroyed, and window means associated with said chamber for introducing said laser illumination into said chamber. Thus, it is an object of the subject invention to provide a low-cost, fool-proof means for producing coal combustion gas streams significantly free of particulates larger than about 2 to 5 microns and which are suitable for directly driving gas turbines; which comprise destroying particles, above a predetermined size, entrained in a gas flow. It is another object of the subject invention to provide a means for destroying such particles which will consume only a very small amount of energy in comparison to the energy of the gas flow. It is also within the contemplation of the subject invention to provide means for injecting particles of various chemical species into the gas stream so that when they are exploded by the laser illumination they will react with and neutralize other objectionable chemical species present in the gas stream and/or replenish protective coatings on downstream components of the system. Means for such injection of particulates would be obvious to those skilled in the art and will not be discussed further herein. Other objects and advantages of the subject invention will become apparent from the discussion to follow. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a preferred embodiment of the subject invention. (Hidden lines shown for window assemblies 20 are typical.) FIG. 2 is a cross-sectional view along 2--2 showing details of the penetration of the cavity wall. FIG. 3 is a cross-sectional view along 3--3 showing details of the window assemblies. FIG. 4 is a schematic representation of a power generating system incorporating subject invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The embodiment discussed is based on the use of the subject invention in a 1000 Mw(e) coal-fired combined cycle power plant having the following estimated parameters: ______________________________________Coal throughput 108 kg/secExcess air 10%Air throughput (870° C., 25 atm) 177 m.sup.3 /secMean particle diameter 10μCoal-ash load to the turbine (coal is 10%ash, 20% of the ash leaves the combustorand 90% of that is trapped by electrostaticprecipitators or cyclones) 216 g/secCoal-ash volume fraction 4.52 × 10.sup.-7Mean particle velocity perpendicularto the beam path 88.5 m/sEnergy density incident upon theparticle 20 J/cm.sup.2Energy to vaporize a particle 1.1 × 10.sup.-8 JEnergy to fracture a sphere and increaseits surface area by 400% 4 × 10.sup.-10 JLaser pulse length 1 μsecLaser wavelength 10.6μ______________________________________ It should be noted that the coal-ash loading is based on the removal of particles larger than approximately 10 microns by the use of cyclones or electrostatic precipitators. Both of these technologies are well established and would be well known to those skilled in the art. Also, the mean particle diameter is taken, as a worst case approximation, to be the approximate maximum particle diameter remaining after the gas has passed through conventional cyclones or electrostatic precipitators. Of prime importance to the subject invention is the manner in which laser light and dust particles interact. Light may be absorbed, transmitted, or scattered causing the pellet to melt, vaporize, or fracture. Only light which is absorbed and causes a reduction in particle size is used effectively. Scattered light will eventually appear as heat in the turbine inlet stream, but such a process is only of very minor interest since the power in the laser beam must be orders of magnitude smaller than the thermal power carried by the gas flow. The dust particles interact with radiation of wavelengths similar to the particle diameters which have been observed by workers in several diverse fields in the past. Astrophysicists have made a study of light passing through dilute clouds of dust. Weapons programs have studied the interaction of dust particles in an air environment with intense bursts of laser light. Research into laser optics and mechanisms of laser damage has shown that particles of a size similar to or smaller than the principle wavelength of the laser suspended in glass will be destroyed at energy densities similar to those proposed for the subject invention. Catastrophic events have been observed in small particles for photon energy densities near 20 J/cm 2 . Slightly higher photon energy densities (within a factor of 2) are needed in order to completely vaporize coal-ash particulates with a 1μ sec. pulse length. The following publications provide a more detailed description of the interactions between laser light and dust particles and are hereby incorporated by reference. The information contained while providing helpful background is not believed essential to a practical understanding of the invention. H. C. Van de Hulst, "Light Scattering by Small Particles," J. Wiley and Sons, New York, 1957. *A. Edwards, J. Fleck, Jr., "Status of Navy "Dirty Air" Breakdown Research," UCID, 17350, LU, December, 1976. *A. Edwards, N. Ferriter, J. Fleck, Jr., A. M. Winslow, "A Theoretical Description of the Interaction of a Pulsed Laser and a Target in an Air Environment," LCRL-51489, November, 1973. R. W. Hopper, D. R. Uhlnaan, "Mechanism of Inclusion Damage in Laser Gloss," J. Appl. Phy., 41, 10, pp. 4023-4037, October, 1970. D. W. Fradin, "Laser-Induced Damage in Solids," Laser Focus, pp. 39-43, February, 1974. L. I. vanTorne, "Pumping Induced Imperfections in Glass, Nd 3+ Lasers," Phy. Stat. Sol., 16, 171, pp. 171-182, 1966. Lasers capable of providing the necessary energy density are well within the current state of the art. CO 2 lasers are preferred since they provide light of a suitable wavelength, 10.6μ, and are commercially well developed. Suitable suppliers of laser systems would include: Systems Science and Software P. O. Box 4803 Hayward, Calif. 94540 and, Lumonics Research Laboratory P. O. Box 1800 Kanata, Ontario Canada Referring now to FIG. 1, the apparatus of the subject invention 10, comprises an intake duct 12, for providing a flow of hot, pressurized, particulate carrying gas, a laser cavity 14, wherein particles are destroyed by exposure to intense laser illumination, an exhaust duct 16 for carrying the hot, pressurized gas, free of large particulates, to turbines for the production of electrical energy, and window assemblies 20 for admitting the laser light into cavity 14. Mirrors 22 may also be provided so that the lasers (not shown) need not be mounted directly in line with window assemblies 20. Preferably the lasers may be mounted alternately above and below the plane of the laser cavity. The hot, pressurized gases may be produced by burning coal by any of the conventional means known in the art. Further ducts 12, 16 are conventional in design and function and need not be discussed further in the description of the subject invention. Referring now to FIG. 2 it can be seen that the laser cavity 14 comprises an outer shell 30 of a material such as low carbon steel which is lined with an insulating layer 32 approximately 10 cm thick of a ceramic material such as alumina or magnesia. Such construction is conventional in power plants and is necessary to prevent heat loss from the gas stream, and also serves to protect outer shell 30 from the laser beams. The height h of cavity 14 is approximately 20 cm and the width w is approximately 10 m giving for the air flow described above a mean particle velocity perpendicular to the cavity cross-section of approximately 88.5 m/sec. The height h, of cavity 14 is limited by the diameter of the laser beams in a manner which will be described below. The width w, of cavity 14 is determined by the absorbtion of the laser energy by the gas stream and the shadowing effect of the particles in a manner which will be described below. The laser beams travel through window assemblies 20 (which will be described more fully below) and enter the cavity 14 through openings 34 approximately 30 cm×20 cm in size. There are 20 such openings 34 and associated assemblies 20 on each side of cavity 14 giving a total active length 1, of approximately 6.62 meters (allowing for the wall thickness of assemblies 20) which gives a pulse repetition rate of approximately 13.5 pulses per second, for a particle velocity of 88.5 meters/sec. (Only 5 of window assemblies 20 and openings 34 have been shown for ease of illustration.) The laser beams as illustrated would illuminate approximately 82% of the active volume of cavity 14 which is approximately 13.24 meters 3 . Preferably, however, the beams would be angled approximately 1° to 2° into the gas flow so as to form a chevron pattern of illumination. This would serve to prevent problems which might arise should the laser illuminate each other directly during an interruption of gas flow. This effect would slightly increase to volume illuminated. This angle has not been shown in the figures for ease of illustration. Similarly, the divergence of the laser beams will tend to increase the volume illuminated. Preferably, the divergence should be minimal so as to maintain the energy density as the beam crosses the cavity. The effects of a divergence of approximately one milliradian, which is obtainable, are negligible. Illumination of approximately from 50% to 90% of the active volume of cavity 14 is considered acceptable since the anticipated reduction in errosion should significantly increase the turbine blade life, while some erosion due to undestroyed particles is considered desirable to combat corrosion. The one micro-second laser pulse length given above is chosen to satisfy several constraints. Shorter pulses, as opposed to near continuous wave operation, force the particles to fragment, due to shock formation, rather than heat up. However, shorter pulses, for a given energy per pulse, increase the power density which tends to cause ionization of the gas. Ionization is undesirable as it leads to unproductive absorbtion of laser energy in the gas stream. Taking 10 8 watts/cm 2 as the ionization threshold from Smith in the Journal of Applied Physics, Vol. 41, pg. 11, Oct. 1970 (which is hereby incorporated by reference) gives an energy density 100 joules/cm 2 for microsecond pulses. However, window materials presently available transparent to 10.6μ light require energy densities below 25 joules/cm 2 to avoid the possibility of damage. Therefore, an energy density of approximately 20 joules/cm 2 has been chosen. It is, however, within the contemplation of the present invention to provide higher energy densities as improved window materials are found. Finally, a pulse length of approximately a microsecond simplifies the laser switching requirements since for pulse lengths below approximately 0.1 microseconds more complicated laser switching mechanisms are required. Referring to FIG. 2 it can be seen that a portion of the laser beam is not directed into cavity 14, but strikes insulating layer 32, since the beam diameter d is greater than the cavity height h. This configuration is necessary to insure that an adequate fraction of cavity 14 is illuminated. The energy which strikes layer 32 is converted to heat which is largely transferred to the gas stream, reducing the energy loss. It is also within the contemplation of this invention to use laser beams having a non-circular cross-section so as to improve the percentage of laser cavity 14 illuminated. Such cross-sections may be produced by the proper shaping and positioning of mirrors 22. For the system as described so far, then, 40 lasers, 20 on each side of cavity 14, each providing approximately 1.4×10 4 joules per pulse with a pulse length of approximately one microsecond, a pulse rate of approximately 13.5 pulses per second and a wavelength of approximately 10μ are required. As indicated above, CO 2 lasers meeting these requirements are well within the current state of the art and would be available from the suppliers listed above, among others. WINDOWS As the beam must pass through a window before entering the combustion product stream, consideration must be given to the demands placed upon such a window. The window material must withstand the high pulsed power densities, transmit efficiently, and not react chemically with the combustion product stream. Furthermore, there must be some way to protect the window from dust. Any dust particles which blow up while either on or very near the surface of the window will lead to unacceptable damage to the window. For 10.6μ irradiation most materials with attractive properties are semiconductors or ionic solids. Attractive properties are: low absorption, high thermal conductivity, low thermal expansion, high specific heat, and low reflective losses. Table 1 lists some of these properties for several infrared materials. Furthermore, the material of choice must be resistant to both thermal and mechanical shock as well. Clearly, materials do presently exist that can survive within the proposed set of conditions. Some precautions and protective measures must be taken, however. None of the materials listed may be expected to operate at the temperature of the combustion product stream (870° C.). Therefore, along with dust protection, thermal protection must be provided. NaCl and CaF 2 will be discarded as materials of choice due to their solubility in water. The remaining materials are to a greater or lesser degree acceptable. Many of the semiconducting windows exhibit thermal runaway (i.e., the absorption increases with temperature). Germanium must be maintained below 40° C. and GaAs must be maintaned below 250° C. for this reason. A supplier capable of supplying suitable windows is: Laser Optics, Inc. POB 127 Danbury, Conn. 06810 Referring to FIG. 3 window assembly 20 comprises a window 40 formed from one of the materials listed in Table 1, or from a similar material. Preferably, window 40 will be a disk of GaAs, approximately 3 to 5 cm thick having a diameter slightly greater than 30 cm. Window 40 is mounted in window tube 42 which comprises an outer tube 43 of a material such as 1/4 inch carbon steel and ceramic insulating lining 44 approximately 1 cm thick preferably formed from alumina or magnesia. Dust-free cooling air, at a temperature of approximately 100° C. blows through inlets 46 and over window 40. The cooling air flows along tube 42 and out through outlets 48. The cooling air may then be vented to the atmosphere after any treatment necessary to reduce emission and/or recover waste heat. Several considerations are important in the design of window assembly 20. With the incoming cooling air at a temperature of approximately 100° C. and the gas stream at a temperature of approximately 870° C. the window assembly 20 should have a length of approximately 10 m in order to establish the necessary temperature gradient. Care must then be taken to establish the pressure, flow rates and flow patterns of the cooling air so that there is minimal escape of hot gases into window assembly 20, as this would represent an undesirable energy loss and the presence of significant amounts of CO 2 in window assembly 20 would cause unacceptable attenuation of the laser beam. Such design consideration may easily be taken into account by a person skilled in the art. Supports, not shown, preferably should also be provided at the window end of assembly 20 since the end attached to cavity 14 will be more exposed to the high temperature gas stream and possibly weakened. Still referring to FIG. 3, it is preferred that the laser, not shown, be mounted not directly in line with window assembly 20, but be offset for ease of mounting, assembly, access, etc. The beam may then be directed through window 40 by means of mirror 22. Suitable mirrors may be formed from turned copper. It is also preferred that the pressure gradient across window 40 be minimal. This necessitates that the laser, not shown, and mirror 22 be at a pressure approximately equal to that of the gas stream. The pressure vessel needed for this is not shown for ease of illustration. Referring now to FIG. 4, there is shown a schematic representation of a power generating system incorporating the subject invention. Coal may be burned by any of several methods well-known in the art in Reactor 50. Hot combustion gases are drawn off from Reactor 50 and prefiltered by conventional means 55, such conventional means may include conventional or modified cyclones and/or electrostatic precipitators. The gases, which now contain essentially no particulates greater than about 10 microns in size, are now passed through the apparatus of the subject invention 10, wherein said particulates are destroyed. The hot pressurized gases may now be used to directly drive turbine 60 for the generation of electrical power by generator 65. GENERAL DESIGN CONSIDERATION AND CONSTRAINTS FOR OPTIMUM PERFORMANCE In light then of the description of the preferred embodiment, the following general design considerations are apparent: (1) The laser wavelength is constrained for reasons of energy density requirements and absorption efficiency, to be approximately equal to or less than the mean particle diameter. (It should be noted that as lasers having a shorter wavelength and sufficient power become available, they may prove to be more desirable than the presently preferred 10.6μ CO 2 lasers.) (2) Given the laser wavelength, the choice of window materials is determined by the absorption of energy of the material at that wavelength. As in the embodiment discussed above means for protecting the window may have to be provided, however, for shorter wavelengths, glass windows requiring less protection may be suitable. (3) Given the laser wavelength the width of the cavity is determined by the absorbtion of energy in the gas stream and/or the shadowing effect and the need to maintain sufficient energy density to insure particle destruction effect. By shadowing effect herein is meant columns created behind particles (with respect to the path of the laser beam) when the particle scatters or absorbs laser light wherein no particles may be destroyed due to attenuation of the beam. For 10.6μ light the absorbtion by CO 2 and H 2 O in the gas stream is the dominant effect. For the example discussed above the intensity (due to a single beam is given approximately by: I(x)=I.sub.o e.sup.-2.7×10.spsp.-3.sup.x where I o is the beam intensity when the beam enters the cavity and x is the distance traversed by the beam in centimeters. This limits the cavity width (for two sided illumination) to approximately 10 meters. For shorter wavelengths the shadowing effect may become more important than absorbtion. An approximate function for the extinction distance (D), which determines cavity width, when shadowing is dominant, (for two-sided illumination) is: D=2d/1.5η where d is the mean particle diameter and η is the volume fraction of particles. (4) The minimum energy density per pulse is constrained by the energy required to insure destruction of particles. This in turn is determined by the size distribution of the particles. A conservative assumption is that the entire particle mass is made up of particles of maximum size. (5) The maximum power density is constrained by the need to avoid damage to the windows and/or ionization of the gas stream. (6) The pulse length is determined by the need to deliver at least the minimum energy density per pulse in as short a pulse as possible (to encourage fragmentation of the particle) while not exceeding the power density constraints or requiring excessively complex laser switching mechanisms. (7) Given the energy density per pulse (power density x pulse length) beam diameter is determined by the maximum energy per pulse available lasers of the chosen wavelength are capable of providing. (8) Given the beam diameter the cavity height is determined by the need to insure that a sufficient fraction of the cavity volume is illuminated. (9) Given the cavity height and width the mean velocity perpendicular to the cross-section is determined by the cross-sectional area. (10) Given the mean velocity the minimum number of lasers is determined by the maximum pulse repetition rate lasers of the chosen specifications are capable of providing. Additional redundant lasers may be provided to increase system reliability. It will be obvious to those skilled in the art that other embodiments than that discussed above may be developed within the scope of the disclosure of the subject invention. Therefore, the above description of the preferred embodiment should be considered as illustrative and not limiting, the limitations on the scope of the claimed invention being set forth only in the claims set forth below. TABLE 1__________________________________________________________________________Thermal and optical properties of some candidate window materials. ZnSe Ge GaAs Si CaF.sub.2 NaCl__________________________________________________________________________Absorption .0005 .03 .02 .036 .005 0.0013cm.sup.-1 @10.6μ @10.6μ @10μ @10.6μ @3.8μ @10.6μThermalconductivityW/mC .08 .59 .40 1.63 .10 .09Thermalexpansioncoeffic.°C..sup.-1 8.5 × 10.sup.-6 5.5 × 10.sup.-6 5.7 × 10.sup.-6 4.2 × 10.sup.-6 2.4 × 10.sup.-5 3.89 × 10.sup.-5SpecificheatJ/g° C. .36 .31 .27 .70 .85 .85__________________________________________________________________________
An apparatus and method for the destruction of particles entrained in a gas stream are disclosed. Destruction in the context of the subject invention means the fragmentation and/or vaporization of particles above a certain size limit. The subject invention contemplates destroying such particles by exposing them to intense bursts of laser light, such light having a frequency approximately equal to or less than the mean size of such particles. This invention is particularly adopted to the protection of turbine blades in open cycle coal-fired turbine systems. Means for introducing various chemical species and activating them by exposure to laser light are also disclosed.
8
FIELD OF THE INVENTION The invention relates to a method and a device for carrying out at least one function assigned to an instruction code. More particularly, the method, respectively the device, represents a space-efficient and flexible mechanism for implementing a virtual machine in a resource-constrained environment such as a smartcard, particularly a smartcard offering a Java environment, such as a Javacard. TECHNICAL FIELD AND BACKGROUND OF THE INVENTION In a system environment with constrained resources such as limited code storage area, usually a ROM, limited application storage area, usually an EEPROM, limited runtime memory, usually a RAM, and limited compute power, i.e, small CPU and low clock cycle rate, the interpretive approach to running applications is well-known. Due to the higher level of abstraction provided by the interpreted code over the machine code, the use of more compact application code is possible, which is an essential requirement in the aforementioned environments. Therefore, the availability of an interpreter is desirable in an embedded system. OBJECT AND ADVANTAGES OF THE INVENTION It is an object of the invention according to claim 1 and 8, to provide a method and a device for executing instruction codes, which require less memory. It is another object of the invention according to claim 1 and 8, to provide a method and a device for executing instruction codes which provides for an easier way to amend the instructions codes, respectively functions which are to be carried out. The above mentioned objects are met by a method according to claim 1 and a device according to claim 8. Regardless of whether the interpreter, also called “virtual machine”, is implemented in software or in hardware, the following two problems are solved: Firstly, the size of the internal main loop serving for the dispatching respectively executing of the codes, herein called “opcodes”, interpreted in the virtual machine, as well as the size and also number of functions necessary to implement the opcodes is reduced. It is most advantageous to get both to the minimum size because of the aforementioned resource constraints in embedded systems, i.e. a system e.g. on a smartcard. Secondly, it might be desirable to be able to change and/or enhance the semantics of single opcodes without changing the code of either the main loop or code implementing the other opcodes. The latter is especially important in an area where opcodes can change due to specification changes, error fixes, particularly at the level of single opcodes, or performance improvements requiring the modification/addition of single opcodes. The approach using a virtual machine which is designed for interpreting or carrying out instructions which are identified by an instruction code whereby the addresses of the functions implementing the opcodes which the virtual machine interprets, as well as parameters to those functions are kept within lookup tables, yields two primary benefits: First, the main interpreter loop is very small, and due to the parameter table, generic functions can be referred to by the opcode table, thus leading to a very space-efficient representation of the virtual machine code. Second, by placing these tables into a mutable memory, such as an EEPROM, error-fixing as well as general maintenance of the virtual machine is feasible at the level of single opcodes even after production of the actual hardware. SUMMARY OF THE INVENTION The invention uses generic opcode tables in conjunction with parameter tables. The idea is to use two types of lookup tables at the core of the virtual machine implementation. The first table, called also “opcode lookup table”, contains for each opcode the address of a function implementing its semantics. As these functions might be generic, i.e., serve for several opcodes as their implementation, a second, discriminating table, also called “parameter lookup table”, is used. Both tables contain the same number of entries, which is identical to the number of opcodes understood by the respective virtual machine. The tables can also be unified to one single table with the opcodes, the functions and the parameters as entries. Especially in a scenario, where many functions can be shared between opcodes, this approach is advantageous: Only a minimum number of these generic routines, which hence results in an according minimum requirement of code size, need be employed because of the use of the functionality-discriminating parameter table. For example, it is assumed that such a scenario of function-sharing for opcode implementations is common if a virtual machine originally intended for a non-resource-constrained environment has to be semantically stripped down to run in a resource-constrained environment. Therewith, the reduction of the functionality of the virtual machine eventually leads to a reduction in complexity of many opcodes, in turn leading to the aforementioned opportunity to create generic functions. Execution of the virtual machine main loop then can proceed as follows: An opcode to be interpreted is loaded from memory. The address of the opcode-realizing function is looked up from the opcode lookup table. A parameter for this function is read from the parameter lookup table. This part of the procedure is optional. Possibly no parameter may be needed. The lookup then returns no parameter or a read parameter can be ignored by the function. The parameter can be loaded into a unique address, e.g., a variable. The function for the instruction code is called and executed. The function returns, and the next opcode is fetched and executed. This way, the code of the core of the virtual machine does not need modification, even if new opcodes are added, since the table is in that case just extended. Also, if old codes are changed, address and parameter entries can be simply changed at the index corresponding to the respective opcode. If opcodes are to be removed, table entries can be invalidated. By the invention's concept, the implementation of the virtual machine core and the implementation of each single opcode are separated. This yields the following advantages: The virtual machine core is extremely small in size. By having the lookup tables reside in immutable memory, e.g. a ROM, an implementation of a virtual machine can be secured against future changes. By having the lookup tables reside in mutable memory, e.g. EEPROM, an implementation of a virtual machine can be changed after delivery of the implementation to the customer. Although optimizing compilers are known to build memory-efficient jump tables for the alternative implementation of a virtual machine core, i.e., CASE or SWITCH statements, they have four primary disadvantages solved by the proposed concept: First, they still bear an overhead due to the inclusion of the inevitable ‘JMP’ machine code statement, which is necessary, since executable code must be the result of a compiler/linker. Second, they always reside in the immutable area shared with all machine code. Third, it is impossible to only change single cases, i.e., implementations of single opcodes after the code has been produced, i.e., put into ROM or hardware. Fourth, compiler-generated optimizations are highly compiler-dependent and cannot be relied on to be done correctly on all platforms. The advantage of the proposed solution is that it works on all system architectures the virtual machine is intended to work in, without change. In fact, if the virtual machine core were implemented in hardware, by putting the lookup tables into mutable memory, this approach would permit the enhancement of a hardware-based virtual machine even after production “in the field”, i.e., even after a customer has started to use it. This is an invaluable advantage if resources are scarce, thus not permitting an update of the complete virtual machine if only single opcode's implementations need enhancements. DESCRIPTION OF THE DRAWINGS An example of the invention is depicted in the drawing and described in detail below by way of example. It is shown in an arrangement with a virtual machine and a memory section for the lookup functions for instruction code. The figure is for sake of clarity not shown in real dimensions, nor are the relations between the dimensions shown in a realistic scale. DETAILED DESCRIPTION OF THE INVENTION In the following, the various exemplary embodiments of the invention are described. As shown in the figure, a protocol-handling unit 15 , denoted with “PHU”, comprises a device driver 16 , denoted with “DD”, and a read-write unit 17 , denoted with “RW”. The PHU 15 communicates bidirectionally with a virtual machine 10 , also called “VM”, serving as control means, which comprises a main loop unit 11 , also called “ML”, and a function section 12 , also called function memory, in which a set of possible functions Function 1 , Function 2 , Function 3 , Function 4 is stored in form of machine code. Each function Function 1 , Function 2 , Function 3 , Function 4 is addressable via an identifier Fn 1 , Fn 2 , Fn 3 , Fn 4 . The VM 10 provides a program counter PC which is assigned to a virtual machine instruction-code-storing means 14 in which code sequences 18 which belong to methods which themselves belong to applets are stored. Applets are collections of data and the therewith-operating methods. The code sequences 18 consist of single instruction codes opcode 1 , opcode 2 , opcode 3 , opcode 4 , opcode 5 , opcode 6 . The virtual machine instruction-code-storing means 14 , also called code memory or CM 14 , is communicated with by the ML 10 which again communicates with a first table means 23 and a second table means 24 which both together with a heap memory 26 form part of a memory unit 25 , here exemplarily an EEPROM, short EE. The outputs of the table means 23 , 24 lead back to the function section 12 to which the heap memory 26 is bidirectionally connected. The PHU 15 further is connected to a random-access memory or RAM 20 which comprises an APDU-object-storing section 21 , short AO, and a stack-storing section 22 , short St. This St 22 has a bidirectional connection to the function section 12 of the VM 10 and is bound to a stack pointer SP which is provided by the ML 11 . The RW 17 can bidirectionally exchange data with the memory unit 25 . An initialization unit 13 , denoted “Ini”, is receiving external input via a Power-On line PON and is providing its output to the PHU 15 . The PHU 15 receives external input via an input line which delivers application protocol data units, short APDUs. An applet administration unit, also called runtime environment 19 , short RTE 19 , is communicating bidirectionally with the VM 10 . The depicted arrangement is preferably arranged on a portable carrier, such as a smartcard, or Javacard. The card can be inserted into a card reader which provides an interface towards external circuitry which communicates with the smartcard via this interface. The interface is to a high degree standardized. APDUs arrive via the card reader at the DD 16 of the PHU 15 . The PHU 15 can handle various types of APDUs, which types are “SELECT” APDUs, “READ EE” APDUs, “WRITE EE” APDUs and other APDUs, herein called “standard” APDUs. The type of APDU which is arriving is recognized in the PHU 15 . During an initialization phase, the initialization unit 13 is active. Upon power on, arriving via the PON line, which simply may be the necessary electrical power needed to run the card circuitry, and a reset signal, inter alia the St 22 is cleared, the PC and the SP are reset, the RAM 20 is cleared, the heap memory 26 is initialized and in the St 22 a system APDU object is initialized in that an APDU object header is written. The PHU 15 is then enabled and waiting for input. As next step, upon arrival of a first APDU which is a SELECT APDU, in the case, when a default applet has not been chosen as the so-called “current applet”, the SELECT APDU is recognized by the PHU 15 , such that the applet in the CM 14 which is identified by the SELECT APDU is selected to be the current applet. Each stored applet contains a number of methods, among which inter alia is stored a process-method, a select-method, an install method and a deselect-method. The arrival of a standard APDU triggers the use of the predetermined current applet for the standard APDU, and more particularly the process-method of the current applet. The VM execution start address of the process-method of the current applet is the address where the first to execute instruction code opcode 1 - 6 for that process-method is stored in the CM 14 . This address is known by the RTE 19 which provides via the VM 10 for the PC being set on that address in the CM 14 . The VM 10 begins to interpret the instruction code sequence 18 from the VM execution start address on. This interpretation comprises the determination of the respective functions to be carried out for this instruction code sequence 18 , starting with the function Function 1 - 4 for the first instruction code opcode 1 - 6 of that instruction code sequence 18 . Therefor, the instruction code opcode 1 - 6 at the address which the PC points to is fed to the first table means 23 which for every possible instruction code opc 1 - 6 comprises the respective function identifier Fn 1 - 4 which identifies the function Function 1 - 4 which is assigned to the respective instruction code opcode 1 - 6 . The instruction code opcode 1 - 6 at the address which the PC points to is also fed to the second table means 24 which for every possible instruction code opc 1 - 6 comprises the respective parameters P 1 , P 2 , P 3 which belong to the identified function Function 1 - 4 for this instruction code opcode 1 - 6 . This feeding is executed by the ML 11 . The found function identifier Fn 1 - 4 together with the identified parameters P 1 , P 2 , P 3 is delivered to the function section 12 where the function identifier Fn 1 - 4 is used to address the storage cell where the respective function Function 1 - 4 is stored. This addressing is again carried out by the ML 11 which then effects that the identified function Function 1 - 4 is then carried out. The functions can perform various actions. A function Function 1 - 4 can e.g. access the heap memory 26 or the stack-storing section 22 and can thereby modify the SP and/or the PC of the VM 10 . As long as the St 22 is not empty, the PC is incremented either by one step or by the number of steps, an instruction code opcode 1 - 6 contains as function Function 1 - 4 , i.e. a “Goto” or “Jump” function Function 1 - 4 . After completing the function Function 1 - 4 for the last instruction code opcode 1 - 6 of a method, the stack pointer SP arrives at a predetermined value indicating to the VM 10 that the stack-storing section 22 is empty. Then, the control is given back to the PHU 15 which returns data, such as status data via the OUT line to the card reader and then expects the next APDU to arrive. The PHU 15 receives the APDUs and stores them, but usually only one at a time, in the RAM 20 at the area of the APDU object payload, assigned to the existing object header which was generated during the initialization phase. In the RAM 20 , the APDU object is stored, which is then accessible by the instruction codes. Thereby, the instruction codes can access data which is needed to perform a particular action, e.g. reading a number representing a monetary value which is to be charged onto a storage cell, which represents the saldo of an account. In the case, when a SELECT APDU is recognized by the PHU 15 , the current applet is used, but now as a first action the deselect-method thereof is to be used instead of the process-method. The respective instruction code sequence 18 of the deselect-method is hence executed via the VM 10 . Afterwards, as a second action, a new current applet is selected according to the information from the SELECT APDU and for the new current applet the select-method is executed by the VM 10 . When a READ APDU is recognized, then the VM 10 is not activated but the memory unit 25 is directly accessed by the PHU 15 for a read-operation, whose result is then output to the card reader via the OUT line. When a WRITE APDU is recognized, then the VM 10 is not activated but the memory unit 25 is directly accessed by the PHU 15 for a write-operation, using the respective part of the content of the WRITE APDU as the new content of a specific memory cell in the memory unit 25 . The processing of READ APDUs and WRITE APDUs may be disabled via a suited mechanism, be it a hardware- or a software-implemented mechanism, to avoid misuse of these APDUs for forbidden actions on the smartcard. The tables 23 , 24 can be unified to one single table which then contains only one address to determine the function identifier Fn 1 - 4 and the corresponding parameters P 1 , P 2 , P 3 in ony single step. This saves time and memory. The tables can be stored in non-mutable as well as in mutable memory. The use of mutable memory is advantageous since then changes in the assignment between functions and instruction codes are easily executable. Also a mixed use of mutable and non-mutable memory can be suitable, particularly when some content of the tables is to be protected from erroneous or even intentional amendment and other content is to be rendered easily accessible for such amendments. Basic functions and/or a sort of default settings can e.g. be stored in non-mutable memory, to preserve card functionality in any case. A new function Function 1 - 4 can be added to the set of available functions Function 1 , Function 2 , Function 3 , Function 4 in that the new function Function 1 - 4 is entered in a mutable new-function memory and that the identifier Fn 1 - 4 in the first table 23 is changed to identify the new function Function 1 - 4 in the mutable new-function memory. The mutable new-function memory can be a separate memory section, but of course be also unified or identical with the function memory 12 . For an instruction code opcode 1 - 6 which is at least temporarily no longer needed, an identifier Fn 1 - 4 can be entered in the first table 23 which signalizes that no function Function 1 - 4 is to be executed. The number of instruction codes, storage cells, functions a.s.o. is exemplary only and hence not limited to the herein chosen number. Additionally another heap memory 26 can be arranged in the ram 20 , which heap memory 26 can also be accessible by the functions. (Javacard is a trademark of Sun Microsystems, Inc.)
A space-efficient and flexible mechanism for implementing a virtual machine in a resource-constrained environment such as a smartcard is proposed. The virtual machine is designed for interpreting or carrying out instructions which are identified by an instruction code, also called opcode. Both, the addresses, respectively identifiers, of the functions implementing the instruction codes, respectively opcodes, which the virtual machine interprets, as well as parameters to those functions are kept within lookup tables.
6
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a continuation application of International Application PCT/NL2015/050432, entitled “Biopolymer extraction”, to Technische Universiteit Delft, filed on Jun. 11, 2015, which claims priority to Netherlands Patent Application Serial No. 2012987, filed Jun. 12, 2014, and the specifications and claims thereof are incorporated herein by reference. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0002] Not Applicable. INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COM-PACT DISC [0003] Not Applicable. COPYRIGHTED MATERIAL [0004] Not Applicable. FIELD OF THE INVENTION (TECHNICAL FIELD) [0005] The present invention is in the field of extraction of a biopolymer from a granular sludge, a biopolymer obtained by said method, and a use of said method. BACKGROUND OF THE INVENTION [0006] In a prior art reactor set up a (non-axenic) bacteria culture may be fed with a suitable carbon sources, in an aqueous environment. Therein dense aggregates of microorganisms are formed, typically in or embedded in an extracellular matrix. Such may relate to granules, to sphere like entities having a higher viscosity than water, globules, a biofilm, etc. [0007] At present, the sludge produced from, e.g., wastewater treatment processes, including granular sludge, is considered as a waste product, having no further use. On top of that, costs of waste disposal are high. [0008] Surprisingly, it has been found that extracellular polymeric substances, in particular linear polysaccharides, obtainable from granular sludge can be produced in large quantities. [0009] Granules making up granular sludge are (dense) aggregates of microbial cells self-immobilized through extracellular polymeric substances into a spherical form without any involvement of carrier material. A characterizing feature of granules of granular sludge is that they do not significantly coagulate during settling (i.e., in a reactor under reduced hydrodynamic shear). Extracellular polymeric substances make up a significant proportion of the total mass of the granules. [0010] Extracellular polymeric substances comprise high-molecular weight compounds (typically >5 kDa) secreted by microorganisms into their environment. Extracellular polymeric substances are mostly composed of polysaccharides and proteins, and may include other macro-molecules such as DNA, lipids and humic substances. [0011] Advantageously, granules of granular sludge can be readily removed from a reactor by e.g. physical separation, settling, centrifugation, cyclonic separation, decantation, filtration, or sieving to provide extracellular polymeric substances in a small volume. Compared to separating material from a liquid phase of the reactor this means that neither huge volumes of organic nor other solvents (for extraction), nor large amounts of energy (to evaporate the liquid) are required for isolation of the extracellular polymeric substances. [0012] Extracellular polymeric substances obtainable from granular sludge (preferably obtained from granular sludge) do not require further purification or treatment to be used for some applications, hence can be applied directly. When the extracellular polymeric substances are obtained from granular sludge the extracellular polymeric substances are preferably isolated from bacteria (cells) and/or other non-extracellular polymeric substances. [0013] However, for various applications the extracellular polymeric substances, in this document also referred to as “biopolymers”, can not be used directly, e.g. in view of insufficient purity, a typical (brownish) coloring of the extracellular polymeric substances, etc. [0014] With the term “microbial process” here a microbiological conversion is meant. [0015] Some documents recite isolation of alginate from aerobic granular sludge. [0016] Li et al. in “Characterization of alginate-like exopolysaccharides isolated from aerobic granular sludge in pilot plant”, Water Research, Elsevier, Amsterdam, NL, Vol. 44, No. 11 (Jun. 1 2010), pp. 3355-3364) recites specific alginates in relatively raw form. These alginates are typically not suited for further use as these are at least partially colored. In the process active carbon may be used, but that is mainly for removing impurities from the solution. Also the lipid content of the alginates is rather low (<1 wt. %). [0017] U.S. Pat. No. 3,856,625 A recites an alginate-type polysaccharide is obtained by the aerobic cultivation of a bacterium of the species Azotobacter vinelandii in an aqueous nutrient medium containing sources of carbon, molybdenum, iron, mangesium, potassium, sodium, sulfate, calcium and phosphate. The carbon source comprises at least one monosaccharide or disaccharide. Contrary to normal culture conditions for this bacterium, for good polysaccharide production, the phosphate concentration in the nutrient medium is 0.1-0.8 millimolar, and the pH of the medium is maintained within the range of from 7.0 to 8.2. [0018] The present invention relates to a method of extraction of a biopolymer from a granular sludge, a biopolymer obtained by said method, and a use of said method, which overcomes one or more of the above disadvantages, without jeopardizing functionality and advantages. BRIEF SUMMARY OF THE INVENTION [0019] The present invention relates in a first aspect to a method according to claim 1 . There with a simple and effective method is presented for extracting biopolymers from dense aggregates formed by microbial organisms. The method specifically relates to extracting an anionic biopolymer. In a step of the method the pH is increased by addition of at least 1-20% v/v of at least one of Cl2, OCl— and H2O2. The addition of the Cl2, OCl— or H2O2 is found to cause discoloration of the biopolymer. This step may be performed at an elevated temperature, or at an (close to) environmental temperature. The present method is typically carried out in a reactor. The extraction is preferably carried out under mixing, such as by stirring. After increasing the pH the biopolymer may be extracted by one or more subsequent steps. [0020] The obtained biopolymers resemble those of the prior art, but are different in certain aspects, such as characterized in the claims; i.e., chemical and physical characteristics are different, such as a lipid content is much higher (2-5 wt. %). The different characteristics result in different applications of the present biopolymers now being possible, or likewise being impossible, compared to those of the prior art. So apart from the discoloration obtained, which is much better than the only partial discoloration (so not effective) of, e.g., Lin et al., the present biopolymers are different in various technical aspects. [0021] In the present application amounts are calculate on a total volume, or total weight, of the dense aggregates, unless stated otherwise. [0022] It is noted that numbering of the various steps are given for a better understanding of an optional sequence of the steps. Some of the steps may be performed in a different order, and/or at a later or earlier stage. [0023] Thereby the present invention provides a solution to one or more of the above mentioned problems. [0024] Advantages of the present invention are detailed throughout the description. DETAILED DESCRIPTION OF THE INVENTION [0025] The present invention relates in a first aspect to a method according to claim 1 . [0026] The present method may be further optimized by in an initial stage removing larger particles, such as by sieving. Preferably particles with a diameter larger than 500 μm are removed, more preferably particles larger than 300 μm, such as larger than 200 μm. Therewith it has been found that the present method is more effective, less energy consuming, and a higher yield of biopolymer is obtained. [0027] The present method may be further optimized by removing part of the water being present, thereby increasing an amount of aggregates. In an example, after providing the sludge, water is removed to a 1-40% w/v content of the wet sludge, more preferably 5-38% w/v, even more preferably 10-35% w/v, even more preferably 20-32% w/v, such as 25-30% w/v. For better understanding also a solid contents fraction may be used. In the latter case solid contents are typically in the range of 0.1-30% w/w, preferably 1-10% w/w, most preferably 4-10% w/w, such as 5-8% w/w. The present method is found to be more effective if part of the water is removed in an initial stage. [0028] In an example the present method comprises the step of (iiia) reducing the pH, preferably until gel formation, such as to a pH of 2-4, by addition of an acid, such as HCl. The present biopolymer is now obtained in an acid form. As such the biopolymer can be collected with ease. [0029] In an example of the present method comprises the step of after reducing the pH (iiib) removing the sludge by one or more of physical separation, settling, centrifugation, cyclonic separation, decantation, filtration, sieving, and flotation, under suitable conditions. Especially good results have been obtained by centrifuging the sludge. [0030] In an example of the present method the biopolymer is bacterial aerobic granular sludge or anammox granular sludge, and is selected form exopolysaccharide, preferably comprising mannuronic acid and guluronic acid residues, block-copolymers comprising uronic acid residues, alginate, lipids, and combinations thereof, or wherein the biopolymer is an algae biopolymer. Especially bacterial aerobic granular sludge or anammox granular sludge has been found to produce high amounts of biopolymers, in good quality. By nature the biopolymers produced as such vary in their characteristics, e.g., composition, molecular weight, etc. [0031] In an example of the present method the granular sludge has been substantially produced by bacteria belonging to the order Pseudomonadaceae, such as pseudomonas and/or Acetobacter bacteria (aerobic granular sludge); or, by bacteria belonging to the order Plancto-mycetales (anammox granular sludge), such as Brocadia anammoxidans, Kuenenia stuttgartiensis or Brocadia fulgida ; or, combinations thereof. [0032] In an example of the present method step (iic) further comprises addition of one or more of a salt comprising a base, such as bicarbonate, hydroxide, and thick bleach, preferably a monovalent salt thereof, such as a Na-salt and a K-salt, an oxidant, such as ozone, and peroxide. Therewith the quality, homogeneity and yield of the biopolymer can be further optimized. [0033] In an example of the present method after step (iic) (a) the temperature is increased to 50-100° C., such as tot 80-85° C., during a period of 10-60 min, such as 20-30 min, preferably under stirring, or (b) the temperature is maintained at 10-30° C., such as at 15-20° C., during a period of 60-2880 min, such as 120-1440 min, preferably under stirring. So at least two variants exist, one with a relative higher temperature and a relative shorter processing time, and one with a relative lower temperature and a relative longer processing time. In view of energy consumption the latter variant is preferred. [0034] In an example of the present method after step (iic) a suspension of the sludge is centrifuged, such as at 2000-6000 rpm, during 10-45 minutes, and a supernatant is collected for further processing. [0035] In an example of the present method after step (iiia) (iiib) the acidic gel is centrifuged, such as at 2000-6000 rpm, during 10-45 minutes, and a supernatant is collected for further processing. [0036] In an example of the present method the extracted biopolymer is further treated, such as by precipitation, such as by addition of an alcohol, by desalination, by osmosis, by reverse osmosis, by salt-formation, such as Na-salt, by neutralising, by adding a base, by drying, by storing, and by freezing. Therewith a product is obtained that can be used in a further application, that can be sold, and that can be stored. [0037] In a second aspect the present invention relates to a use of the present method for discolouring biopolymers obtained from aerobic granular sludge or from algae. It has been found that particular in this respect the present method is very suited. [0038] In a third aspect the present invention relates to a special biopolymer, obtained by the present method. The present biopolymers may be characterized by various parameters. They may be different in various aspects from e.g. known comparable chemically or otherwise obtainable polymers, such is in viscosity behaviour, molecular weight, hydrophobicity, lipid content, microstructure (as can be observed under an electron microscope), etc. For instance, the lipid content of the present biopolymers is much higher than those of prior art comparable biopolymers, namely 2-5 wt. %, such as 3-4 wt. %. Analyses of an exemplary biopolymer using a PerkinElmer 983 double beam dispersive IR spectrometer shows approximately 3.2 wt. % peaks that are attributed to lipids. Typically the present biopolymers are also less pure, i.e., a mixture of polymers is obtained. [0039] The present biopolymer may relate to an alginate, such as ALE. This is different from the alginates e.g. obtainable by the above pilot plant alginates in various aspects. For instance it may have a decreasing dynamic viscosity with increasing shear rate (@ 25° C.), wherein a relative decrease is from 5-50% reduction in dynamic viscosity per 10-fold increase in shear rate. It may have a dynamic viscosity of >0.2-1 Pa*s (@ 25° C., @ shear rate of 1/sec). It may have a number averaged weight of >10,000 Dalton, preferably >50,000 Da, such as >100,000 Da. It may have a hydrophilic part and hydrophobic part. It may relate to a discoloured biopolymer. And it may relate to combinations of the above. [0040] In an example of the present biopolymer it may have >30% with a molecular weight of >300,000 Da, >10% with a molecular weight of >100,000 Da, >15% with a molecular weight of >5,000 Da, and <10% with a molecular weight of <5,000 Da. [0041] In a third aspect the present invention relates to a use of the present biopolymer in one or more of a stiff or flexible coating, such as a coating for steel, for concrete, for food, such as cheese, for packaging, such as for food packaging, for anti-graffiti, for optics, for polymer feed stock, for catalysis, for mixed (nano)composites, such as clay-alginate-silicate, and graphene-alginate, as a paper additive, for a self-healing coating, for medical application, as an additive in general, for an electrochemical device, such as a battery, and for separation, such as gas separation. [0042] The invention is further detailed by the accompanying figures and examples, which are exemplary and explanatory of nature and are not limiting the scope of the invention. To the person skilled in the art it may be clear that many variants, being obvious or not, may be conceivable falling within the scope of protection, defined by the present claims. SUMMARY OF FIGURES [0043] FIG. 1 a -1 c shows the effect of shear rate on viscosity of ALE and commercial alginate. DETAILED DESCRIPTION OF FIGURES [0044] The figures are further detailed in the description of the experiments below. Examples/Experiments [0045] The invention although described in detailed explanatory context may be best understood in conjunction with the accompanying examples and figures. [0046] Below exemplary embodiments of a method of extraction of a specific biopolymer (microbial alginate; ALE) is given. Note that various steps are optional. [0047] Hot Extraction of ALE from Granular Sludge [0048] 1) Sieve the granular sludge to collect granules diameter more than 200 μm, then wash with tap water. [0049] 2) Remove the excess water using tissue paper placed under the sieve. [0050] 3) Before starting the extraction, take ±1 gram of sludge for dry weight determination. Measure the empty cup, the filled cup and put in the oven (105° C.) to dry. Weigh again if dried. [0051] 4) Prepare granules suspension in tap water with a Total Solids TSS content of about 3%. This corresponds with 30-35 gram wet weight sludge in a total volume of 100 mL. [0000] Before adding the water, preheat it to save time in step 5. [0052] 5) Add thick bleach solution to reach 10% (v/v). [0053] 6) Mix thoroughly and place the suspension in a water bath on a hotplate stirrer set to 80° C. and 400 rpm, for 30 min. Add aluminium foil to the top to prevent evaporation. [0054] 7) Collect the suspension in 50 mL tubes and centrifuge the liquor at 4500 rpm for 20 min. Collect the supernatant in a glass beaker and discard the pellet. [0055] 8) Adjust the supernatant pH to 2.5 by adding 4 M HCl on a magnetic stirrer. Collect the acidic gel in 50 mL tubes. [0056] 9) Centrifuge the acidic gel at 4500 rpm for 10 min, and then collect the pellet. [0057] 10) The acidic gel can be stored at 4° C. or frozen. [0058] The gel can be further prepared according to purpose/client for example in the following ways: [0059] (a) To prepare Na-ALE. [0060] (b) To precipitate the Na-ALE, and [0061] (c) To prepare salt-free/low salt Na-ALE by desalination. [0062] (a) To prepare Na-ALE: [0000] Add 0.5 M NaOH to the acidic gel to reach the required concentration. [0063] (b) To precipitate the Na-ALE: [0000] Add ethanol 1:1 volume. Discard the supernatant and let the Na-ALE to dry in the oven at 85° C. [0064] (c) To desalinate: [0065] Put Na-ALE in SnakeSkin® dialysis tubing (3,500 MWCO*) with a volume capacity of (3.7 ml/cm); close the tubing ends by knotting or with tubing clips after edges folded over twice and leave overnight in a glass beaker with milliQ water while stirring. [0066] Cold Extraction of ALE from Granular Sludge [0067] 1) Sieve the granular sludge to collect granules diameter more than 200 μm, then wash with tap water. [0068] 2) Remove the excess water using tissue paper placed under the sieve. [0069] 3) Before starting the extraction, take ±1 gram of sludge for dry weight determination. Measure the empty cup, the filled cup and put in the oven (105° C.) to dry. Weigh again if dried. [0070] 4) Prepare granules suspension in tap water with TSS of about 3%. This corresponds with 30-35 gram wet weight sludge in a total volume of 100 mL. [0071] 5) Add thick bleach solution to reach 10% (v/v). [0072] 6) Mix thoroughly and place the suspension at room temp or 4 c for 24 hours. Add aluminium foil to the top to prevent evaporation. [0073] 7) Collect the suspension in 50 mL tubes and centrifuge the liquor at 4500 rpm for 20 min. Collect the supernatant in a glass beaker and discard the pellet. [0074] 8) Adjust the supernatant pH to 2.5 by adding 4 M HCl on a magnetic stirrer. Gel formation can be noticed with foam. If there is no foam, keep adding HCl. [0075] 9) Collect the acidic gel in 50 mL tubes and discard the foam from the top (containing some insoluble solid impurities). [0076] 10) Centrifuge the acidic gel at 4500 rpm for 10 min, and then collect the pellet. [0077] 11) The acidic gel can be stored at 4° C. or frozen. [0078] The gel can be further prepared according to purpose/client as indicated above in the hot extraction section. ALE Molecular Weight Analysis [0079] Size exclusion chromatography was performed with a Superdex 75 10/300 GL column (AKTA Purifier System, GE Healthcare). Elution was carried out at room temperature using Phosphate Buffer Saline (PBS) containing 10 mM (HPO42-, H2PO4-) with a pH of 7.4, and further having 2.7 mM KCl and 137 mM NaCl, at a constant 0.4 mL/min flow rate. The detection was monitored by following the absorbance of the eluted molecules at a wavelength of 210 nm. [0080] The Superdex 75 10/300 GL column is capable of separating molecules of 1,000 to 70,000 Daltons (Da). Measurement of the elution volume of dextran standards (i.e. 1000 Da, 5000 Da, 12000 Da, 25000 Da and 50000 Da) led to the calibration equation: [0000] Log(MW)=6.212−0.1861 Ve; [0000] Wherein MW: Molecular Weight of the molecule in Dalton (Da), and Ve: elution volume in mL (assayed at the top of the peak). [0081] Chromatogram profiles were recorded with UNICORN 5.1 software (GE Healthcare). Peak retention times and peak areas were directly calculated and delivered by the program. Results [0082] [0000] TABLE 1 Molecular weight of different fractions in alginate-like exopolysaccharides and their percentage. Elution volume Percentage of the of the peak Molecular weight fraction (ml) (kDa) (% peak area) 7.83 >70 29.74 13.48 14.4 18.82 15.57 5.79 45.15 17.58 2.15 4.42 20.13 0.656 1.87 Rheology Experiments [0083] Viscosity is considered to be an important parameter for biopolymers, such as alginate. Rheology studies the phenomena that appear during deformation and flow of fluids, solids and of solid systems under the influence of external forces. Newton's law is considered to apply for fluids such as to ideal elastic and viscous materials. [0084] Rheological experiments are performed to determine the viscosity versus the shear rate, the critical overlap concentration, the thermal stability and the salinity stability. The viscosity is measured as a function of shear rate using an AR-G2 Rheometer. Materials and Method [0085] The rheology experiments are performed in an AR-G2 Rheometer using Couette Geometry. The Rheometer is filled with 20 ml samples of the polymer solution Na-ALE in the desired concentrations and salinity's. The alginic acid is converted to the desired polymer solution (sodium alginate (Na-ALE)) by adding NaOH and deionized water. [0086] To prepare the polymer solution samples for the rheology experiments a stock solution of the highest concentration is prepared first. Thereafter the highest concentration stock solution is diluted to the desired (lower) concentrations. The stock solution is prepared as follows: [0087] The amount of alginic acid required is weighted with a mass balance. [0088] Subsequently NaOH (0.1 N) is added gently to the solution to avoid particle agglomeration. [0089] The solution is stirred and the pH is measured continuously. [0090] NaOH (0.1 N) is added up to a final pH of approximately 8.3 and the solution is supplemented to the required volume with deionized water. [0091] The beaker is stirred for 30 minutes at high speed and covered with aluminum foil to prevent contact with air. [0092] Subsequently, the stirrer is reduced to medium speed and the solution is stirred and degassed for at least one day to create a homogeneous polymer solution in equilibrium and to guarantee hydration. [0093] Finally the stock solution is diluted with deionized water to 20 ml of polymer solution to the desired concentrations. Results [0094] The viscosity of ALE and alginate solutions at various shear rates is shown in FIG. 1 a - c ). The viscosity (vertical axis, Pa*s) of ALE decreases as the shear rate increases (horizontal axis, 1/s). This is shown for four different solutions, from top to bottom, having 5%, 3%, 2%, and 1% alginate, respectively. Apparently the present solutions, comprising the present ALE, show non-Newtonian behavior in this respect. [0095] In comparison, in FIG. 1 b the viscosity of algae alginate is affected less by changing shear rate. This is shown for five different solutions, from top to bottom, having 10%, 5%, 3%, 2%, and 1% algae alginate, respectively. [0096] Such is considered an indication that the solution of ALE is more pseudoplastic than that of comparable algae alginates. This property may provide advantages in processing, such as pumping and filling.
In a prior art reactor set up dense aggregates of microorganisms are formed, typically in or embedded in an extracellular matrix. Such may relate to granules, to sphere like entities having a higher viscosity than water, globules, a biofilm, etc. The dense aggregates comprise extracellular polymeric substances, or biopolymers, in particular linear polysaccharides. The present invention is in the field of extraction of a biopolymer from a granular sludge, a biopolymer obtained by such method, and a use of such method.
2
BACKGROUND The present invention relates generally to a reclinable motorcycle backrest, and more particularly to a reclinable motorcycle backrest with a saddle cover having a sun blocking function. In general, a motorcycle saddle, when exposed to sunshine for a period of time, becomes very hot and uncomfortable for riders to sit on. The riders have to cover the saddle with something or move the motorcycle to a shaded area for some period of time in order to keep it cool. For the foregoing reasons, there is a need to provide a sun-proof material to prevent saddles from being overheated. Moreover, the motorcycle backrest of the prior art is normally fixed in position, and thus it can not provide a covering function by reclining it forward. SUMMARY OF THE INVENTION In view of shortcomings as described above, it is therefore an object of this invention to provide a new reclinable motorcycle backrest with a sun-proof saddle cover which extends from the slot on the back of the backrest. This invention includes: a support bracket having a set of receptacles each with an arresting recess mounted on the motorcycle cargo rack; a backrest assembly including: a main body having a soft pad on one side and a retraction compartment on the other side, jointed pivotally at bottom ends with the support bracket; a scroll having one flat end protruding out of the main body; a roll of sun-shielding cloth having one end fixed onto the scroll; a back-cover board having a slot for covering the roll of sun-shielding cloth stored in the retraction compartment wherein the sun-shielding cloth is pulled out through the slot; a crank bar having a cranking hole, composed of a long hole and a round hole, at one end; and a fixing pivotal rod having two latching ears used to latch on the arresting recess to stop the backrest assembly from reclining down. The sun-shielding cloth is wrapped around the scroll to form a sheath to hold the scroll and is secured by a slotted steel tubular clip. Further, at the end of the crank bar, is a slidable roll-pin with a ball shaped knob at one end and a grooved neck at the other end which is inserted in a first opening on the side-wall of the backrest assembly to prevent the crank bar from rocking. There is a second opening which is perpendicular to the first opening, working with a ball headed pin pressed against the grooved neck of the roll-pin and a second compression spring to stop the roll-pin from sliding out of the first opening. The roll-pin has a first compression spring which is butted between the crank bar and the ball shaped knob so as to spring out the roll-pin of the second opening. The cross section of the fixing pivotal rod is square, and the latching ears have square holes to let the fixing pivotal rod slide through. BRIEF DESCRIPTION OF THE DRAWINGS The present invention can be more fully understood by reference to the following detailed description and accompanying drawings, which form the integral part of this application, and wherein: FIG. 1 is a diagram of the structural assembly of the reclinable motorcycle backrest according to the present invention; FIG. 2 is an exploded view of the structural assembly of the reclinable motorcycle backrest according to the present invention; and FIG. 3 shows a reclined backrest assembly with a fully stretched saddle cover according to the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 1, the reclinable backrest with a sun-proof saddle cover in this invention includes a support bracket 1, and a backrest assembly 2 jointed pivotally at bottom ends with the support bracket 1 by a long rod 2J. Both the backrest assembly 2 and the support bracket 1 have arresting recesses 1a2, 1a2' on each side so that they can hold two latching ears 3b, 3b' fixed on two ends of the slidable fixing pivotal rod 3 which runs through the square rod-holes 1a5-1a5' and 2a5-2a5' on the support bracket 1 and the backrest assembly 2 respectively. When the reclinable backrest assembly is erected in an up-right position, the slidable fixing pivotal rod 3 is pushed to a position so that the latching ears 3b,3b' can rest on the arresting recess 1a2, 1a2' so as to stop the reclinable backrest assembly from reclining down. The following is the detalied description of the components and their relationship in the assembly structure of this invention: Referring to FIG. 2, the support bracket 1 has four groove butts 1a with holes fitted onto the motorcycle cargo rack 4. On two sides of the upper part of the support bracket 1 are a set of receptacles 1a8 and 1a8' having grooves 1a1, 1a1'; arresting recesses 1a2, 1a2' form cut-outs on the side-walls of the receptacle. The arresting recesses 1a2, 1a2' are formed by a first protuberance 1a6' and a second protuberance (not shown), and a first flat end 1a7' and a second flat end (not shown). Below these elements are rod-holes 1a5, 1a5'. The backrest assembly 2 includes a main body 2a, a scroll 2b, a roll of sun-shielding saddle cover sheet 2c, a back-cover board 2d having a slot 2k, a cut out portion 2d 2 , a cover portion 2d 3 ; and a crank bar 2e. The main body 2a looks like a solid U-shaped board with a wall 2a6 around its rim. A soft pad 2a1 is bolted to the base plate of the main body 2a with two bolts 2a8. The U-shaped wall and the base plate form a retraction compartment 2a2 wherein the roll of sun-shielding saddle cover sheet is stored. There are two bumps at the lower ends of the main body 2a. However, only one bump is shown and indicated by reference character 2a3'. On the left side of the wall 2a6 are the rod holes 2a5 and a pit 2a4. On the right side of the wall 2a6 are another rod hole 2a5' and the other pit 2a4', and a first opening 2a7 which is met by a second opening 2a7' drilled from the top of the wall and is therefore perpendicular to the first opening 2a7. The scroll 2b is a round rod having one end ground to form a neck 2b1 and a head 2b2, and a roll-pin eye 2b3 for a wire or roll-pin to be inserted through. One end of the roll of sun-shielding cover sheet 2c may be sewn to form a scroll-sheating portion 2c4 for holstering the scroll 2b, while another end may be sewn to holster a steel tube 2c1. A rubber string going through the tube 2c1 to form a sling handle 2c2. The crank bar 2e has an insertion hole 2e1 consisting of a long hole 2e11 and a round hole 2e12, wherein the width of long hole 2e11 matches the diameter of the neck of the scroll 2b1 and the diameter of the round hole 2e12 matches the diameter of the scroll 2b. On the other end of the crank bar 2e is a roll-pin 2e2 which has a protrusive cap 2e21 and a neck 2e13 at one end , and a ball-shaped knob 2e14 on the other end. Besides, there is a spring coil 2e15 freely stretched in between the crank bar 2e and the balled-shaped knob 2e14. Also shown in FIG. 2 are rollers 2d 1 and supports 5,5'. The slidable fixing pivotal rod 3 is basically a square shaft with one end through a square hole 3a on the latching ear 3b, and the other end going through the other latching ear 3b'. At the tip of one end of the rod 3, there are threads 3c and spring coil 3e for fastening the screw cap 3d. The following is the assembling procedure: First, run scroll 2b through the round hole 2e12 of the crank bar 2e and the scroll-sheathing portion 2c4 of the saddle cover sheet 2c. Next, insert a wire or roll-pin through the roll-pin eye 2b3 on the scroll 2b so as to fix the scroll 2b onto the main body 2a in a pivotal manner. In the meantime, attach the saddle cover sheet 2c and the crank bar 2e to the main body 2a. Then clamp the scroll-sheathing portion 2c4 of the saddle cover sheet 2c and the sheathed scroll 2b with a slotted steel tubular clip 2c3 to ensure the saddle cover sheet 2c com roll with the scroll 2b when cranking motion starts, otherwise the scroll 2b may not be able to grip the saddle cover sheet and will just keep spinning within the scroll sheathing portion 2c4. Through the long hole 2e11 matched with the head 2b2 of the scroll 2b, the crank bar 2e can roll up the saddle cover sheet 2c around the axis of the scroll 2b. To form a retraction compartment, first insert a ball-headed pin 2g, along with a compression spring 2h around its shaft, into the second opening 2a7' on the wall top of the main body 2a; then screw the back-cover board 2d onto the main body 2a. The handle tube 2c1 should be extended out through the slot 2k on the back-cover board 2d. Finally run the long rod 2J through the first rod hole 1a4 of the support bracket 1 and the rod-holes 2a5, 2a5' of the backrest assembly 2 so as to pivotally fix the backrest assembly 2 to the support bracket 1. Run the slidable fixing pivotal rod 3 with a third compression spring 3e capped with a screw head 3d, through the first square rod-hole 1a5', the right latching ear 3b', the left latching ear 3b, and the left square rod-hole 1a5; and thus the assembling procedure is completed. In addition, two handgrip straps are installed onto the sides of the cargo rack 4 and the support bracket 1 by screw bolts. There also is a guiding rod 9 running through the retraction compartment to ease the roll-out motion. Next, the operational instruction is, as follows: Referring to FIG. 1, the backrest assembly is shown in an up-right position where the roll-pin 2e2 of the crank bar 2e is inserted in the first opening 2a7. To cover the saddle, first depress the screw cap 3d and push the slidable fixing pivotal rod 3 inwards (as pointed by the arrow a) to a position that the latching ears 3b, 3b' slide out of the arresting recess 1a2 and 1a2'; meanwhile, the backrest assembly 2 may recline downwards or towards the front of motorcycle(as pointed by the arrow b); then, pull the sling handle 2c2 hanging outside of the back-cover board 2d until the cover sheet 2c is spread out enough to reach the hook 6 on the handset of the motorcycle (as shown in FIG. 3.) When it is no longer needed, first pull out the roll-pin 2e2 from the first opening 2a7, and then adjust the long hole 2e11 of the crank bar 2e until it aligns with the neck 2b1 of scroll 2b; and then snap it on. In the meantime, crank the crank bar 2e to roll up the saddle cover sheet 2c until it is fully retracted into the backrest assembly 2. After retracting the cover sheet 2c, move the round hole 2e12 of the crank bar 2e to align with the circular part of scroll 2b; then push the roll-pin 2e2 into the first opening 2a7. Concurrently, the ball headed pin 2g of the second opening 2a7', driven by the compressed spring 2h, is butting against the neck 2e13 of the roll-pin 2e2 to prevent the roll-pin 2e2 from springing out of the first opening 2a7 under the exertion of spring 2e15. To resume the up-right position, all that is needed is to pull up the backrest assembly 2 until the latching ears 3b, 3b' click into the arresting recess 1a2, 1a2' respectively; this stops the backrest assembly 2 from reclining down. The invention has been described above in terms of some important, preferred embodiments; however, this invention is not limited to the disclosed embodiments. On the contrary, for a person skilled in the art, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest possible interpretation so as to encompass all such modifications and similar structures and processes.
A reclinable motorcycle backrest having a sun-shielding saddle cover mounted on a motorcycle cargo rack, includes a support bracket, a backrest assembly, and a pivotal rod tying the other two pieces together. Stored in the backrest assembly is a roll of sun-proof shielding cloth functioning as a motorcycle saddle cover sheet which is extractable from a retraction compartment by cranking a crank bar alongside the assembly. The backrest may be erected in an up-right position when used in carrying passengers or may be reclined forward with its cover sheet extended out to cover the saddle so that the saddle stays cool even when in strong sun.
1
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority from provisional patent application Ser. No. 61/336,646 filed Jan. 25, 2010 pursuant to one or more of 35 U.S.C. 119, §120, §365. The entire contents the cited provisional patent application is incorporated herein by reference for all purposes. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a female threaded fastener or thread clamping device wherein a single device is capable of robustly engaging threaded rods of different diameters as well as threaded rods having different thread configurations, including both English (inch) and metric rods and threads. [0004] 2. Description of the Prior Art [0005] The fastener industry employs many examples of threaded female fasteners with moving segments that facilitate quick connection or assembly of the fastener to the threaded rod when assembled in one direction along the threaded rod, but locks when motion is attempted in the opposite direction along the threaded rod. That is, the fastener can be moved along a threaded rod in one direction rapidly and without rotation (hereinafter the “ratcheting” direction), but locks when translational motion without rotation is attempted along the rod in the opposite direction (hereinafter the “locking” direction). Thus, rotation of the fastener is required to move the fastener in the locking direction. Upon moving the fastener to the desired position in the ratcheting direction and applying an external torque to tighten the fastener, the torque applied to the fastener will drive the segments into the threaded rod if the fastener base can rotate, but not cause the fastener to move axially along the rod, thus providing locking friction between the segment threads and the rod threads. [0006] However, existing fasteners can be used only with the particular thread configuration and only with a rod of the correct diameter for which the fastener was designed. That is, different fasteners are required for each rod diameter and for each thread configuration. Thus, a need exists in the art for fasteners capable of clamping robustly to rods of different diameters and to rods having different thread configurations, in particular, fasteners capable of clamping robustly to rods and threads fabricated according to either English (inch) or metric standards or to rods having different threads within the same standard. SUMMARY OF THE INVENTION [0007] One important characteristic of the fasteners described herein (referred to as “Multi-Thread Clamping Device” or M-TCD) is that the M-TCD is capable of successfully and robustly engaging two or more rods with totally different threads. That is, a single M-TCD as described herein can be used to engage any rod chosen from a group of rods having different thread structures and/or rod diameters. The diameter range of different rods and the number of different thread types that can be engaged by a single M-TCD depends on several factors in the structure of the particular M-TCD as described more fully below. [0008] In brief, the M-TCDs described herein engage the threads on a threaded rod (or simply “rod”) by means of a number of threaded, movable segments wherein the threads of each segment are capable of robust engagement with the threads of a rod, typically different segments or groups of segments capable of binding with different thread structures. [0009] The structure of threads on threaded rods may be defined according to profile geometry, diametral pitch, axial pitch and dimension, among other characteristics. See for example, Machinery's Handbook, 28 th Ed. (Industrial Press, 2008), pp. 1708-2026. The diameter of the rod also affects the geometry of the threads. For economy of language, we use “thread type”, “thread structure”, “thread geometry” and the like to denote a particular thread on a rod with a particular diameter. [0010] The movable segments of the M-TCD typically have different thread structures capable of engaging corresponding thread structures on different types of rods. That is, each movable segment (or set of segments) of an M-TCD will be designed to meet the standards for a particular thread on a particular rod. Thus, if the particular M-TCD has segments meeting the standards for N different thread types, that single type of M-TCD is suitable for engaging N different thread types (limited by geometrical factors in that rods having substantially different diameters cannot both engage robustly with the segments of a single M-TCD since a single M-TCD cannot conveniently bring segments into intimate engagement with rods of very different diameters). [0011] Advantageously, these various movable segments having different threads within a typical M-TCD are considered in “sets” wherein each segment in a given “set” has the same thread structure. The individual segments comprising such sets are advantageously disposed more or less in an equidistant polar configuration about the M-TCD central axis. That is, a segment set is generally a group of threaded movable segments typically having approximately the same physical size with the same thread pitch diameter and the same thread pitch (the axial distance between the same features on adjacent threads). All segments typically produce an inward radial force component when the segment threads are engaged by the rod threads in a locking direction. “Balanced” and “unbalanced” segment sets may exist. A balanced segment set produces inward radial force vectors that sum substantially to zero. An unbalanced segment set produces inward radial force vectors that do not sum to zero. If there are an even number of total segments within the M-TCD, then each segment set is inherently balanced as long as each segment set has the following properties. [0012] (a) Each segment set has the same total number of segments as any other segment set. [0013] (b) Each segment set has all segments configured in an equidistant polar array. [0014] (c) All the segments within a segment set are approximately the same physical size. An M-TCD with an odd total number of segments typically will have unbalanced segment sets. Each segment of a particular segment set has a specific thread geometry comprising a specific thread pitch diameter and thread pitch axially along the rod. Each segment within the segment set will typically have the same thread geometry. However the thread phase may vary from segment to segment. Thread phase is most readily understood by considering a hypothetical operation of axially cutting a standard threaded nut into four equal quarters, the quarters of this divided standard nut are analogous to segments of the M-TCD. If any the position around the perimeter of any of the two nut quarters are exchanged and then all quarters are reconnected (welded) together, the resulting re-assembled nut would not engage (or screw) on to a threaded rod because the threads of the re-assembled nut are out of phase with respect to the two quarters of the original nut that were exchanged. In contrast, an M-TCD will operate correctly whether or not the segments within a segment set have the same thread phase because the segments are movable and will align to the phase of the rod thread. [0015] Each segment set of the M-TCD engages a rod with a matching thread and will not engage a threaded rod with a mismatched thread (a rod with a different thread pitch diameter and/or axial thread pitch). It is possible for a particular segment having a particular thread structure to engage more than one threaded rod having slightly different thread pitch diameters (approximately within 15% of each other), but the axial thread pitch must be almost identical to achieve proper thread engagement with the segments of that particular segment set. There is no theoretical limit to the total number of segment sets within the M-TCD, however an M-TCD having two segment sets seems to offer cost effective manufacturing and adequate performance. Thus, to be concrete in our description, the M-TCDs described herein are typically shown as having two segment sets and two segments within each segment set for a total of four segments. Other configurations and numbers of segments and segment sets are clearly envisioned within the scope of this invention, and a few illustrative examples will also be described. But for the particular M-TCD having two segment sets and four total segments, the same M-TCD fastener can be constructed so as to engage with a threaded rod with an American National and Unified Screw Thread Form (typically referred to as “English” or “inch” threads) as well as a threaded rod with an American National Standard Metric Screw Thread (typically referred to as “Metric” threads). The actual thread profile of both thread systems is identical. However the pitches and diameters are different for most standard sizes within each system. To be concrete in our discussions herein we shall use the terms US thread and Metric thread to differentiate between the two systems. In the US system there are two typical thread pitches, a coarse pitch (referred to as UNC or Unified National Coarse) and a fine pitch (referred to as UNF or Unified National Fine). The same is true in the Metric system, but the capabilities described herein apply equally within each thread system and between both thread systems. [0016] In view of the foregoing, in accordance with the various embodiments of the present invention, there is provided a family of M-TCDs able to move along a threaded rod in one direction without rotation (“ratcheting direction”), and further, will not move in the opposite direction without rotation (“locking direction”). Each time the M-TCD moves (slides) at least a one half (½) thread in the downward (ratcheting) direction, the M-TCD is configured to internally ratchet and lock in place, thus preventing the M-TCD from moving upward (in the locking direction) with respect to the (presumed vertical) threaded rod. [0017] Additionally, an advantage of the M-TCD over a traditional hex nut is that the M-TCD will engage many damaged threaded rods successfully where even a substantial portion of the threads of the rod have been deformed to the point where the standard hex nut will jam. These and other features and advantages of the present invention will be understood upon consideration of the following detailed description of the invention and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0018] It should be noted here that some of the following drawings depict internal and/or external threads. The threads illustrated are for explanation purposes and do not always show a true spiral because of imprecision of the CAD software application used to generate the drawings, however the thread profile is accurate. The description of various embodiments of the invention is not affected by this drawing imprecision. [0019] The drawings herein are schematic and not generally to scale. They are not intended to depict absolute or relative dimensions of devices or components. [0020] FIG. 1 is a perspective view of a typical M-TCD on a threaded rod. [0021] FIG. 2 is a top view of a typical M-TCD. [0022] FIG. 3 is a side view of a typical M-TCD. [0023] FIG. 4 is an exploded perspective view of a typical M-TCD. [0024] FIG. 5 is a top view of the base of a typical M-TCD. [0025] FIG. 6 is a sectioned view of the base defined by Section CC in FIG. 5 . [0026] FIG. 7 is a three dimensional top perspective view of a typical M-TCD with cap removed. [0027] FIG. 8 is a sectioned view of the cap only, defined by Section AA in FIG. 2 . [0028] FIG. 9 is a sectioned view of an entire M-TCD defined by Section AA in FIG. 2 . [0029] FIG. 10 is a sectioned view of an entire M-TCD defined by Section BB in FIG. 2 . [0030] FIG. 11 is a close up outer perspective view of a single segment (or movable segment) with smaller thread pitch (more threads per axial inch) than the segment shown in FIG. 12 . [0031] FIG. 12 is a close up outer perspective view of a single movable segment with larger thread pitch (less threads per axial inch) than the segment shown in FIG. 11 . [0032] FIG. 13 to FIG. 22 are schematic top view representations of various M-TCD segment and segment set configurations. Components designated as “A”, “B”, “C” in these figures, whether or not followed by a numerical suffix, indicate distinct segments. [0033] FIG. 13 . A balanced four segment M-TCD. [0034] FIG. 14 . An unbalanced four segment M-TCD. [0035] FIG. 15 . An unbalanced three segment M-TCD. [0036] FIG. 16 . A balanced five segment M-TCD. [0037] FIGS. 17-18 . Unbalanced five segment M-TCDs. [0038] FIG. 19 . A balanced six segment M-TCD. [0039] FIG. 20 . A balanced six segment M-TCD. [0040] FIG. 21 . An unbalanced six segment M-TCD. [0041] FIG. 22 . A balanced twelve segment M-TCD. DETAILED DESCRIPTION [0042] FIG. 1 is a perspective view of a typical M-TCD engaged to a threaded rod (“Rod”) 4 in pursuant to some embodiments of the present invention. [0043] FIG. 2 and FIG. 3 show top view, and side view respectively of a typical M-TCD. FIG. 4 shows in exploded view a typical M-TCD including a base 22 , movable segments (“segments”) 6 and movable segments (“segments”) 7 supported by base 22 , and a cap 8 engaging base 22 with one or more posts 20 . Segments 6 and segments 7 are contained within cap 8 . Surrounding segments 6 and segments 7 is spring 10 . For the particular embodiment depicted in FIG. 2 , we depict two segment sets, one set having two segments 6 , and another set having two segments 7 , symmetrically positioned about the central axis 24 of the M-TCD ( FIG. 8 ). In one embodiment of the present invention, both segments 6 are identical, both segments 7 are identical but different from segments 6 , resulting in a balanced four segment M-TCD. [0044] Hex surface 21 is depicted in FIG. 2 as one convenient configuration for base 22 . It is to be noted that while the base 22 is shown with substantially hexagonal side surfaces, within the scope of the present invention, the base 22 of the M-TCD typically includes cubic, square and any other tubular configuration capable of accommodating threaded rod 4 , and which is capable of including the components and features of the M-TCD as discussed in further detail below. [0045] FIG. 4 , illustrates a complete (four segment balanced) M-TCD with all parts depicted in exploded view. Four posts 20 are shown on base 22 . The four posts 20 on base 22 are used to couple cap 8 to base 22 . Within the scope of the present invention, depending upon the shape of M-TCD among other considerations, a fewer or greater number of posts 20 may be used. [0046] Spring 10 is shown above base 22 . Also in FIG. 4 , segments 6 and segments 7 are shown directly below spring 10 . Cap 8 is also depicted above segments 6 and segments 7 . All the parts illustrated in FIG. 4 , when assembled, comprise one typical example of a complete M-TCD as would be employed for actual field uses. Also shown in FIG. 4 are load bearing surfaces (or “surfaces”) 18 in base 22 . There are, in this example, four load-bearing surfaces 18 arranged in an equidistant polar array relative to central axis 24 in base 22 (see FIG. 6 ). This M-TCD has its central axis 24 coincident with the axis of threaded rod 4 . Left segment guide surface 17 , load-bearing surface 18 and right segment guide surface 19 are defined to be a “feature set”. Also load-bearing surface 18 is advantageously designed to be about 30 degrees relative to central axis 24 . FIG. 4 also shows a segment spring groove 14 . There is one groove 14 , one upper guide surface 12 and one segment load-bearing surface 16 for each segment 6 and segment 7 . [0047] In the following descriptions various configurations of segment sets will be described. Segment sets for segments 6 and segments 7 are shown in FIG. 2 , FIG. 4 and FIG. 7 . Segments within a segment set typically have the same thread geometry. While the thread phase could be different among segments within a segment set it is more economical if all the segments within a set are identical. [0048] FIG. 5 is a top view of base 22 . Shown in top view are surfaces 17 , 18 , 19 and 21 . [0049] FIG. 6 shows load-bearing surfaces 18 at a 30 degree angle to central axis 24 . Now referring back to FIG. 4 , in an assembled configuration, segment load-bearing surfaces 16 bear against load-bearing surfaces 18 of base 22 . During application of clockwise torque upon hex surfaces 21 of base 22 , left segment guide surfaces 17 engage segment right side surface 11 of segment 6 and cause segments 6 to rotate clockwise (when viewed from above in the sense of FIG. 4 ) about rod 4 . Similarly during application of counter clockwise torque upon hex surfaces 21 of base 22 , right segment guide surface 19 of base 22 engages segment left side surfaces 13 of segment 6 and cause segments 6 to rotate counter clockwise about rod 4 . It should be noted that M-TCD will operate correctly even if left segment guide surface 17 of base 22 and right segment guide surface 19 of base 22 do not engage segment right side surface 11 of segment 6 and segment left side surface 13 of segment 6 respectively, provided that load-bearing surface 18 of base 22 is engaged with segment load-bearing surface 16 of segment 6 . It should also be noted that, although both sets of segments 6 and segments 7 are rotated with respect to rod 4 as the entire M-TCD is rotated, for the particular example considered here, only segments 6 actually engage the rod threads (as shown in FIG. 9 ) and segments 7 do not engage the threads of rod 4 since the threads of segments 6 , in this embodiment, are assumed to have been fabricated so as to match the threads of rod 4 while the threads of segments 7 are assumed to have been fabricated so as to mismatch the threads of rod 4 (as shown in FIG. 10 ). Segments 7 would be suitable for engaging a different rod 4 having matching threads with those of segments 7 while, in this alternate example, segments 6 would not engage this different threaded rod 4 . Thus, the use of different segments for segments 6 and segments 7 permit this example of an M-TCD to function properly for two different rods. [0050] FIG. 7 is an upper perspective view of base 22 depicting segments 6 with spring 10 in segment spring grooves 14 . Segments 6 are shown in an engaged position and segments 7 are shown in a disengaged position in this example. [0051] FIG. 8 is a sectioned view of cap 8 as defined by Section AA as shown in FIG. 2 . Cap 8 provides two basic functions. First, cap 8 retains segments 6 and segments 7 within the M-TCD using a press fit between press fit cap surface 32 and base post surfaces 28 shown in FIG. 5 . The second function of cap 8 is to provide guiding force for the segments when the segments are moving away from the rod 4 during ratcheting. This guiding is accomplished by cap guiding surface 30 engaging upper guide surface 12 . [0052] FIG. 9 is a cross sectional view of M-TCD as defined by Section AA shown in FIG. 2 with segments 6 engaged with threaded rod 4 in accordance with some embodiments of the present invention. Also shown in cross section is cap 8 , and base 22 along with spring 10 . Also shown are motion direction arrows 50 and 52 that define the direction of motion of segments 6 during ratcheting. [0053] FIG. 10 is a cross sectional view of M-TCD as defined by Section BB shown in FIG. 2 with segments 7 disengaged from rod 4 . Segment threads 46 (mismatched threads in this example) are shown disengaged with rod threads 34 in accordance with some embodiments of the present invention. Also shown in cross section is cap 8 , and base 22 along with spring 10 . Motion direction arrows are not shown in FIG. 10 since segments 7 have mismatched threads 46 with respect rod threads 34 and therefore remain disengaged at all times. [0054] FIG. 11 is a perspective view of movable segment 6 . The threads 40 of segment 6 threads are chosen in this example to match the thread geometry 34 of rod 4 and therefore engage the threads of rod 4 . [0055] FIG. 12 is a perspective view of movable segment 7 . The threads 46 do not match the threads of rod 4 . The thread pitch of segment 7 may be more or less than the pitch of thread 34 of rod 4 . [0056] FIG. 13 is a schematic depiction of a typical M-TCD which has four total segments 56 , 58 . The segments 56 and 58 within M-TCD 54 represent two balanced segment sets 56 and balanced set 58 . Segments 56 are labeled A and segments 58 are labeled B. In the M-TCD 54 configuration all segments are shown as approximately the same size and therefore segment sets 56 and 58 are balanced since all inward force vectors sum to zero. To maintain a balanced configuration all segments 56 must be substantially the same size as all other segments 56 and all segments 58 must be substantially the same size as all other segments 58 . However segments 56 may be a different size than segments 58 . It is possible to have an M-TCD with a single set of segments and only two segments within the set. However, such a device would not be capable of successfully engaging two threaded rods of differing threads which is one major purpose of the M-TCD. [0057] FIG. 14 is a schematic depiction of segments within M-TCD 60 that represent two unbalanced segment sets. Unbalanced segment set 56 and unbalanced segment set 58 . All segments within M-TCD 60 are the same size as the corresponding segments 56 and 58 shown in M-TCD 54 ( FIG. 13 ). However the inward force vectors of segments 56 and 58 do not sum to zero since each segment set is not spaced in an equidistant polar configuration about the M-TCD 60 central axis. [0058] FIG. 15 is a schematic depiction of segments within M-TCD 66 that represent another example of two unbalanced segment sets, unbalanced segment set 62 (two segments) and unbalanced segment set 64 (a single segment). All segments within M-TCD 66 are the same size. However in any M-TCD segment configuration that has an odd number of total segments it is not possible to have a single segment in another segment set where the inward force vectors for all segment sets will sum to zero. [0059] FIG. 16 is a schematic depiction of an M-TCD having an odd number of total segments within M-TCD 70 that comprise two balanced segment sets. Segments 58 represent a balanced set of two segments 58 and the second segment set consists of two segments 68 plus one segment 56 . Two segments 68 equal the size of segment 56 for a total of three segments in the segment set where the sum of the inward force vector does sum to zero thus defining a balanced segment set. This example is disfavored for practical applications since in an actual application it is expected generally to be more economical to replace the two segments 68 with a single segment 56 . [0060] FIG. 17 and FIG. 18 are schematic depictions of five segment M-TCDs demonstrating the example of an M-TCD with an odd number of total segments (where all the segments within each segment set are the same size). The segment sets are unbalanced since the inward force vectors do not sum to zero no matter what the polar distribution of the segments about the central axis of the M-TCD. [0061] FIG. 19 is a schematic depiction of a six segment M-TCD 86 with three balanced segment sets 80 , 82 and 84 . Each segment set has two equal segments and in each segment set the inward force vectors sum to zero. In each segment set there are two segments configured in an equidistant polar array about the central axis of M-TCD 86 . M-TCD 86 is capable of successfully engaging three separate rods of differing thread geometry and/or diameter. [0062] FIG. 20 is a schematic depiction of a six segment M-TCD 88 with two balanced segment sets 80 and 82 . Each segment set has three equal segments and in each segment set the inward force vectors sum to zero. In each segment set there are three segments configured in an equidistant polar array about the central axis of M-TCD 88 . M-TCD 88 is capable of successfully engaging two separate rods of differing thread geometry and/or diameter. [0063] FIG. 21 is a schematic depiction of a six segment M-TCD 90 with two unbalanced segment sets 80 and 82 . Each segment set has three equal segments and in each segment set the inward force vectors do not sum to zero. In each segment set there are three segments configured in a non-equidistant polar array about the central of M-TCD 90 . [0064] FIG. 22 is a schematic depiction of a twelve segment M-TCD 98 with three balanced segment sets 92 , 94 and 96 . Each segment set has four equal segments and in each segment set the inward force vectors sum to zero. In each segment set there are four segments configured in an equidistant polar array about the central of M-TCD 98 . M-TCD 98 is capable of successfully engaging three separate rods of differing thread geometry. M-TCD 98 could easily be configured to have six balanced segment sets where each segment set would consist of two equal segments configured in an equidistant polar array about the central axis of M-TCD 98 . Each segment set of two segments would have the sum of the inward force vectors sum to zero. Such an M-TCD would be capable of successfully engaging six separate rods of differing thread geometry. It is obvious that an almost limitless combination of segment sets and segment sizes in both balanced and unbalanced configurations are possible within an M-TCD. In general, balanced segment sets are the most effective and the more unbalanced a segment set becomes the less effective it becomes. [0065] Referring to FIG. 1 this M-TCD is typically configured to move along threaded rod 4 in one direction (“ratcheting direction”) without rotation of M-TCD, and to resist motion in the opposite direction (“locking direction”) without rotation. For the purposes of describing M-TCD and related embodiments herein, the direction of motion whereby M-TCD moves along threaded rod 4 without rotation shall be defined as the ratcheting direction and the opposite direction of motion as the non-ratcheting or locking direction. In particular, in accordance with some embodiments of the present invention, M-TCD is typically configured to be engaged to threaded rod 4 such that a single downward hand movement of M-TCD down the length of threaded rod 4 will correspondingly move M-TCD in the ratcheting direction accordingly, to a desired or predetermined position on threaded rod 4 . Once in place, an upward hand movement of M-TCD along the length of threaded rod 4 will be met with an equal and opposite force such that M-TCD will not move in the non-ratcheting direction. Rather, in order to move M-TCD in the upward non-ratcheting direction of threaded rod 4 , M-TCD is rotated along the threads of threaded rod 4 . The most common configuration with respect to M-TCD engaged to a vertical threaded rod 4 is where (when viewed from above) a counter clockwise rotation of M-TCD will advance M-TCD upward (non-ratcheting direction) with respect to threaded rod 4 . [0066] It should be noted that while the above description is provided with respect to upward (non-ratcheting) and downward (ratcheting) hand movements of M-TCD along the length of threaded rod 4 , the direction of the movements of M-TCD may be arbitrary depending upon, for example, the orientation of threaded rod 4 to which M-TCD is engaged. [0067] In some embodiments, M-TCD will ratchet whenever M-TCD is moved along threaded rod 4 a minimum of one-half (½) of a thread pitch in the ratcheting direction. That is, when M-TCD moves one half of a thread pitch the segment set that matches the rod thread will ratchet such that if forces try to move the segment set in the opposite non-ratcheting direction, a minimum of one segment will lock up and prevent motion in the opposite direction with respect to threaded rod 4 . To implement ½ thread ratcheting 2 identical segments 6 are arranged opposite one another in two of the possible two positions (shown in FIG. 7 ). [0068] In particular with respect to FIG. 7 and FIG. 9 , each of the two segments are driven upwards and outward at a 30 degree angle relative to central axis 24 as a result of upper guide surface 12 ( FIG. 9 shows guide surface 30 engaging bearing upper guide surface 12 ) engaging cap guide surface 30 as threaded rod 4 (or equivalently the M-TCD) is pushed in the ratcheting direction. In this case, with enough movement of the segments along direction 50 and 52 ( FIG. 9 ), segments 6 will completely disengage the threads of rod 4 , and re-engage when the next rod thread moves into position to allow the two segments 6 to move toward rod 4 center and re-engage the threads of threaded rod 4 . [0069] On the other hand, if the forces reverse in direction and threaded rod 4 is driven down in the non-ratcheting direction (or M-TCD driven up), segments will be driven toward threaded rod 4 and lock. The threads will stay engaged as long as the downward force exists because of the inward radial force pushing segments 6 toward threaded rod 4 . The inward radial force is generated by load-bearing surfaces 18 of base 22 contacting segment load-bearing surface 16 of segment 6 (see FIGS. 4 , 5 and 6 ). Also to be considered is the outward radial force caused by the interaction of thread flanks of rod 4 against lower thread flank 42 of segment 6 ( FIG. 11 ). The inward radial force relative to axis 24 on segment 6 overcomes the outward radial force on segment 6 as long as the “flank angle”, the included angle between lower thread flank 42 of segment 6 and the upper thread flank 44 ( FIG. 11 ) remains approximately 60 degrees (which is the standard flank angle for American Standard and Metric threads), and the angle of load-bearing surface 18 , remains substantially 30 degrees relative to axis 24 , and reversing forces (forces in the non-ratcheting direction) are present. The resultant inward force keeps the segments 6 engaged with threaded rod 4 . [0070] Moreover, in some embodiments of the present invention, the material used to construct segments 6 is chosen to have a yield point greater than or equal to the material used for fabrication of threaded rod 4 . Even when the yield points are substantially similar between the materials for threaded rod 4 and segments 6 , and one segment 6 begins plastic deformation, as soon as threaded rod 4 moves (that is, before all segments of the segment set are fully engaged and resisting the motion of the threaded rod), other segments 6 will start to engage threaded rod 4 to overcome the strength of threaded rod 4 . Actual experiments have shown that upon application of an increasing load on rod 4 while engaged with segments 6 , segments 6 will crush the rod 4 and the rod 4 will fail by separating in two, typically at a point just below the segments 6 . That is, if the system is placed under increasing axial force between the rod and the M-TCD until failure occurs (in the non-ratcheting direction), the rod rather than the M-TCD is the element most likely to fail. The segments 6 are typically much stronger and transfer more load per thread 40 to the rod 4 than a standard hex nut with the same number of threads and of the same thread geometry because the M-TCD provides inward radial forces that place the material of segment 6 threads 40 in compression and not just in shear as is the case with a standard hex nut with non-moving thread elements. [0071] Alternatively, the material for segments 6 , may have a yield point substantially lower than that for threaded rod 4 , in which case threaded rod 4 will still fail (i.e., give way or break off) before M-TCD is compromised if there is sufficient length of thread engagement. [0072] Moreover, spring 10 in some embodiments is configured to have sufficient tension to cause segments 6 to close around threaded rod 4 even in the case where there is gravitational force is pulling segments 6 away from threaded rod 4 (for example, in the case where M-TCD is inverted). Indeed, if segments 6 are not driven toward the center of threaded rod 4 by spring force, segments 6 , may move outward to the wall of cap 8 and remain in that position resulting in M-TCD not engaging with threaded rod 4 . [0073] Referring to the FIG. 9 , the directional arrows 50 and 52 illustrate the line of action in which segments 6 are configured to move when M-TCD moves in the ratcheting direction with respect to threaded rod 4 . [0074] During final assembly of the M-TCD the cap 8 is aligned over the base posts 20 of base 22 and then cap 8 is pushed down over base 22 . The posts 20 force cap 8 outward over the posts 20 until the downward motion of the cap 8 allows the press fit surface ( FIG. 6 ) of base 22 to engage press fit surface 32 of cap 8 ( FIG. 8 ) and be a press fit. The cap 8 now cannot be removed from the base 22 without damage to the cap 8 . This accomplishes the final assembly of the M-TCD without the use of other fasteners. [0075] Referring to FIG. 6 , it is advantageous to employ a conical lead-in 26 to guide the M-TCD over the end of threaded rod 4 upon initial engagement of M-TCD to the end of threaded rod 4 . The conical lead-in 26 causes installation of M-TCD over the end of rod 4 to be quick and easy as the conical lead-in 26 guides the end of threaded rod 4 to the center of M-TCD. The segments 6 then move according to FIG. 9 as previously described as segments 6 engage the end of rod 4 . [0076] Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
Thread clamping devices are described in which a single such device is capable of robustly engaging with different threaded rods having different thread configurations. Such devices include a plurality of threaded, movable segments wherein the threads of each segment are capable of robust engagement with the threads of a rod, and different segments or groups of segments have thread configurations capable of binding with different rod thread structures.
5
RELATED APPLICATIONS [0001] This application is a continuation-in-part and claims the benefit under 35 U.S.C. §120 of U.S. patent application Ser. No. 13/739,054 titled Luminaire with Prismatic Optic filed Jan. 11, 2013, which in turn is related to and claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 61/642,205 titled Luminaire with Prismatic Optic filed May 3, 2012, the contents of which are incorporated in their entirety herein. FIELD OF THE INVENTION [0002] The present invention relates to systems and methods for generating light, and more particularly, a system for effectively distributing light substantially about a light bulb. BACKGROUND OF THE INVENTION [0003] Achieving nearly uniform light distribution about a light bulb has long been a goal in the lighting industry. Success in this goal has largely depended upon the method of providing light employed by the bulb. Specifically, different methods of light generation produce light with different distributions, which must be compensated for in the construction of the bulb. [0004] Most of the earliest light bulbs were incandescent, which generate light by heating a filament wire until it glows. Due to the relatively sparse nature of the supporting structures necessary for the filament, and due to the 360-degree dispersion of light by the filament, achieving nearly uniform distribution about an incandescent light bulb was not difficult to achieve. However, due to inefficiencies in the method of light production employed in incandescent light bulbs, other methods are desirable. [0005] Fluorescent lamps, specifically compact fluorescent lamps (CFLs), have been steadily replacing incandescent light bulbs in many lighting applications. Similar to incandescent, CFLs produce light in approximately 360 degrees by exciting mercury vapor to cause a gas discharge of light. CFLs are more energy efficient than incandescent light bulbs, but suffer a number of undesirable traits. Many CFLs have poor color temperature, resulting in a less aesthetically pleasing light. Some CFLs have prolonged warm-up times, requiring up to three minutes before maximum light output is achieved. All CFLs contain mercury, a toxic substance that must be handled carefully and disposed of in a particular manner. Furthermore, CFLs suffer from a reduced life span when turned on and off for short period. Therefore, there are a number of disadvantages to using CFLs in a lighting system. [0006] Light emitting diodes (LEDs) are increasingly being used as the light source in light bulbs. LEDs offer greater efficiencies than CFLs, have an increased life span, and are increasingly being designed to have desirable color temperatures. Moreover, LEDs do not contain mercury or any other toxic substance. However, by the very nature of their design and operation, LEDs have a directional output. Accordingly, the light emitted by an LED may not have the nearly omni-directional and uniform light distribution of incandescents and CFLs. Although multiple LEDs can and frequently are used in a single light bulb, solutions presented so far do not have light distribution properties approximating or equaling the dispersion properties of incandescents or CFLs. Accordingly, there is a long felt need for a light bulb that can utilize LEDs as a light source while maintaining uniform and nearly omni-directional light distribution properties. [0007] One issue facing the use of LEDs to replace traditional light bulbs is heat. LEDs suffer damage and decreased performance when operating in high-heat environments. Moreover, when operating in a confined environment, the heat generated by the LED and its attending circuitry itself can cause damage to the LED. Heat sinks are well known in the art and have been effectively used to provide cooling capacity, maintaining an LED-based light bulb within a desirable operating temperature. However, heat sinks can sometimes negatively impact the light distribution properties of the light bulb, resulting in non-uniform distribution of light about the bulb. Accordingly, there is a long felt need for an LED-based light bulb capable of providing uniform light distribution that maintains a desirable operating temperature. [0008] This background information is provided to reveal information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention. SUMMARY OF THE INVENTION [0009] With the foregoing in mind, embodiments of the present invention are related to a luminaire that utilizes a prismatic optic to distribute light from a light emitting element within the luminaire approximately uniformly about the luminaire. The luminaire, according to embodiments of the present invention, can also advantageously combine this prismatic optic with one or more light emitting diodes (LEDs) as a light source, overcoming previous deficiencies in LED-based luminaire designs. [0010] These and other objects, features, and advantages according to the presenting invention are provided by a luminaire including a light source and a prismatic optic. The light source may include one or more LEDs that emit light that is incident upon the prismatic optic. The prismatic optic, in turn, may refract the light substantially about the luminaire, resulting in approximately omni-directional and uniform light distribution. The luminaire may further include a base for connection to a light socket and a heat sink for cooling the light source. The base may be attached to the heat sink, which is, in turn, attached to the light source and the prismatic optic. A surface of the heat sink may have reflective properties configured to reflect light generally towards the prismatic optic. The luminaire may further include a circuit board including circuitry configured to power the light source. The circuit board may be positioned so as to be optimally cooled by the heat sink. [0011] The prismatic optic, according to embodiments of the present invention, may be configured to have specific light refracting properties. Specifically, the prismatic optic may refract light within certain regions with certain uniformities. The light may be refracted within regions of 0 degrees to 135 degrees, 135 degrees to 150 degrees, and 150 degrees to 180 degrees. Furthermore, the light may be of uniform intensity to within a certain percentage of an average intensity, such as within 20%, within 10%, within 5%, or within 1%. [0012] The light source may include a platform upon which one or more LEDs may be attached. The LEDs may be attached to an upper surface and/or a lower surface of the platform, increasing light distribution. Furthermore, the platform may include a section within which the LEDs may be attached that facilitates electric coupling between the LEDs and the circuit board. [0013] A method aspect of the present invention is for using the luminaire. The method may include the steps of generating light and refracting light according to a desired light distribution. [0014] In some embodiments, the optic may have a first and second surfaces. The first surface may comprise a plurality of generally vertical and horizontal segments. Furthermore, the second surface may comprise a curvature. In some embodiments, the curvature may be generally concave. The curvature may be within a range from about X degrees to about Y degrees. BRIEF DESCRIPTION OF THE DRAWINGS [0015] FIG. 1 is a side view of a luminaire according to an embodiment of the present invention. [0016] FIG. 2 is a perspective view of a lower structure of the luminaire presented in FIG. 1 . [0017] FIG. 3 is a perspective view of a prismatic optic of the luminaire presented in FIG. 1 . [0018] FIG. 4 a is a partial top view of the luminaire presented in FIG. 1 . [0019] FIG. 4 b is a partial bottom view of the luminaire presented in FIG. 1 . [0020] FIG. 5 is a partial side sectional view of the prismatic optic of the luminaire presented in FIG. 1 . [0021] FIG. 6 is a perspective view of an upper structure of the luminaire presented in FIG. 1 . [0022] FIG. 7 is a partial side sectional view of the upper section presented in FIG. 6 . [0023] FIG. 8 is a perspective view of a light source used in connection with the luminaire presented in FIG. 1 . [0024] FIG. 9 a is a perspective view of a housing used in connection with the luminaire presented in FIG. 1 [0025] FIG. 9 b is a side sectional view of the luminaire presented in FIG. 1 taken through line 9 b - 9 b. [0026] FIG. 10 is a perspective view of a cap used in connection with the luminaire presented in FIG. 1 . [0027] FIG. 11 is a perspective view of the cross section view of the luminaire as presented in FIG. 9 b. [0028] FIG. 12 is a polar graphical illustration representing a light distribution of the luminaire presented in FIG. 1 . [0029] FIG. 13 is a side elevation of a luminaire according to an alternative embodiment of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0030] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Those of ordinary skill in the art realize that the following descriptions of the embodiments of the present invention are illustrative and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Like numbers refer to like elements throughout. [0031] Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention. [0032] In this detailed description of the present invention, a person skilled in the art should note that directional terms, such as “above,” “below,” “upper,” “lower,” and other like terms are used for the convenience of the reader in reference to the drawings. Also, a person skilled in the art should notice this description may contain other terminology to convey position, orientation, and direction without departing from the principles of the present invention. [0033] An embodiment of the invention, as shown and described by the various figures and accompanying text, provides a luminaire 100 . Referring initially to FIG. 1 , a luminaire 100 according to an embodiment of the present invention is depicted, the luminaire 100 including a base 110 , a lower structure 200 , a prismatic optic 300 , and an upper structure 600 . [0034] The base 110 of the present embodiment of the luminaire 100 is configured to conform to an Edison screw fitting that is well known in the art. However, the base 110 may be configured to conform with any fitting for light bulbs known in the art, including, but not limited to, bayonet, bi-post, bi-pin, and wedge fittings. Additionally, the base 110 may be configured to conform to the various sizes and configurations of the aforementioned fittings. [0035] In the present embodiment, the base 110 of the luminaire 100 may include an electrical contact 111 formed of an electrically conductive material, an insulator 112 , and a sidewall 113 comprising a plurality of threads 114 . The plurality of threads 114 may form a threaded fitting on inside and outside surfaces of the sidewall 113 . The electrical contact 111 may be configured to conduct electricity from a light socket. [0036] Turning to FIG. 2 , the lower structure 200 may have a lower section 201 defining a first end 202 and an upper section 203 defining a second end 204 . The interface between the lower section 201 and the upper section 202 may define a shelf 206 disposed about a perimeter the lower section 201 . The shelf 206 may include one or more attachment sections 207 at which the prismatic optic 300 may attach to the lower structure 200 . The first end 202 may be attached to the base 110 at the sidewall 113 by any means known in the art, including, not by limitation, use of adhesives or glues, welding, and fasteners. [0037] Each of the first section 201 and the second section 203 may include a void that cooperates with each other to define a longitudinal cavity 208 . The shape and dimensions of the longitudinal cavity 208 will be discussed in greater detail hereinbelow. The upper section 203 may include a body member 209 having an outside surface 210 . The outer surface 210 may be positioned along a longitudinal axis of the luminaire 100 . The outer surface 210 may be configured to reflect light incident thereupon. The outer surface 210 may have a reflection coefficient of at least about 0.1, or about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9, or about 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, or about 1. In one embodiment, the outer surface 210 may act as a substrate and have a layer of reflective paint applied thereto. The reflective paint may advantageously enhance illumination provided by the light source by causing enhanced reflection of the light prior to reaching the prismatic enclosure 300 , which will be discussed in greater detail below. In another embodiment, the outer surface 210 may have a reflective liner applied thereto. Similarly, the reflective liner may be readily provided by any type of reflective liner which may be known in the art. [0038] The upper section 203 may further include one or more channels 212 formed in the outer surface 210 . The channels 212 may be configured to align with the attachment sections 207 and run parallel to the longitudinal cavity 208 , facilitating the attachment of the prismatic optic 300 to the lower structure 200 . [0039] In the present embodiment, the lower structure 200 may be configured to act as a heat sink. Accordingly, portions of the lower structure 200 may be formed of thermally conductive material. Moreover, portions of the lower structure 200 may include fins 214 . In this embodiment, the fins 214 are configured to run the length of the lower section 201 and extend radially outward therefrom. The fins 214 increase the surface area of the lower structure 200 and permit fluid flow between each fin 214 , enhancing the cooling capability of the lower structure 200 . The fins 214 may have a curved vertical profile to emulate the shape of traditional incandescent light bulbs. Optionally, the fins 214 may be configured to conform to the A19 light bulb standard size. Additional information directed to the use of heat sinks for dissipating heat in an illumination apparatus is found in U.S. Pat. No. 7,922,356 titled Illumination Apparatus for Conducting and Dissipating Heat from a Light Source, and U.S. Pat. No. 7,824,075 titled Method and Apparatus for Cooling a Light Bulb, the entire contents of each of which are incorporated herein by reference. [0040] Furthermore, the lower structure 200 may include interior channels formed in the body member 209 . The interior channels may extend from a first opening 216 in an upper surface 222 of the body member 209 to a second opening 218 in an interior surface 224 of the upper section 203 forming the longitudinal cavity 208 . Air may be permitted to flow through the interior channels, providing additional cooling capability. Alternatively, the lower structure 200 may be formed as a substantially solid structure, not including the various structural aspects intended to increase the cooling capacity as described above. The lower structure 200 may further include a recessed region 220 formed in the upper surface 222 of the body member 209 . The recessed region may extend from the void of the upper section 203 to the outside surface 210 . [0041] Referring now to FIG. 3 , a prismatic optic 300 according to an embodiment of the present invention is depicted. In the present embodiment, the prismatic optic 300 may include an upper optic 310 and a lower optic 350 . The upper optic 310 may be attached to the lower optic 350 by any method known in the art, including, but not limited to, threaded coupling, interference fit, adhesives, glues, fasteners, and welding, or combinations thereof. Moreover, in an alternative embodiment, the upper optic 310 and the lower optic 350 may be integrally formed as a single optic. The prismatic optic 300 is configured to define an optical chamber 301 , wherein the optical chamber 301 is configured to permit a light source to be disposed therein. [0042] The prismatic optic 300 may be formed of any transparent, translucent, or substantially translucent material including, but not limited to, glass, fluorite, and polymers, such as polycarbonate. Types of glass include, without limitation, fused quartz, soda-lime glass, lead glass, flint glass, fluoride glass, aluminosilicates, phosphate glass, borate glass, and chalcogenide glass. [0043] Each of the upper optic 310 and the lower optic 350 may include a sidewall 312 , 352 comprising an inner surface 314 , 354 and an outer surface 316 , 356 . Each of the outer surfaces 316 , 356 may comprise a plurality of grooves 318 , 358 formed thereon. Turning to FIGS. 4 a - b, the grooves 318 , 358 are configured to have substantially straight sides 320 , 360 , the sides forming alternating peaks 322 , 362 and valleys 324 , 364 . The angles formed at the peaks 322 , 362 and valleys 324 , 364 , as well as the length of the sides 320 , 360 may be selectively chosen to alter the refraction of light thereby. [0044] Returning now back to FIG. 3 , each of the outside surfaces 316 , 356 may be configured to have a curvature. The degree of the curvature may be selected according to design standards, such as, a curvature that conforms to an A19 light bulb standard, having a diameter of about 2.375 inches. The curvature may also conform to any other industry standard, including, but not limited to, A15 (about 1.875 inches), A21 (about 2.625 inches), G10 (about 1.25 inches), G20 (about 2.5 inches), G25 (about 3.125 inches), G30 (about 3.75 inches), and G40 (about 5 inches). The preceding are provided for exemplary purposes and are not limiting in any way. [0045] The lower optic 350 may include one or more protruding members 366 extending radially inward from a first end the inner surface 354 . The protruding members 366 may be configured to pass through the one or more channels 212 to interface with the attachment sections 207 , which are depicted in FIG. 2 . Each protruding member 366 may be associated with one channel 212 and one attachment section 207 . Each of the protruding members 366 may be attached to an attachment section 207 , thereby attaching the optic 300 to the lower structure 200 . The protruding members 366 may be attached to the attachment sections 207 by any method that can withstand the forces experienced by the luminaire 100 , such as those experienced during installation and removal. Methods of attachment include, but are not limited to, adhesives, glues, welding, and fasteners. Similarly, the upper optic 310 may include protruding members 326 extending radially inward from a first end of the inner surface 314 . The protruding members 326 may be configured to attach to the upper structure 600 described in detail hereinbelow. [0046] Referring now to FIG. 5 , each of the inner surfaces 314 , 354 may include a plurality of generally vertical segments 328 , 368 and a plurality of generally horizontal segments 330 , 370 . Each of the generally vertical segment 328 , 368 may have two ends and may be attached at each end to a generally horizontal segment 330 , 370 , thereby forming a plurality of prismatic surfaces 332 , 372 . It is not a requirement of the invention that the generally vertical segments 328 , 368 be perfectly vertical, nor is it a requirement that the generally horizontal segments 330 , 370 be perfectly horizontal. Similarly, it is not a requirement of the invention that the generally vertical segments 328 , 368 be perpendicular to the generally horizontal segments 330 , 370 . Each of the prismatic surfaces 332 , 372 may be smooth, having a generally low surface tolerance. Moreover, each of the prismatic surfaces 332 , 372 may be curved, forming a diameter of the inner surfaces 314 , 354 . [0047] The variance of the generally vertical segments 328 , 368 from vertical may be controlled and configured to desirously refract light. Similarly, the variance of the generally horizontal segments 330 , 370 from horizontal may be controlled and configured to produce prismatic surfaces 330 , 370 that desirously refract light. Accordingly, the prismatic surfaces 332 , 372 may cooperate with the grooves 318 , 358 , as depicted in FIGS. 3 and 4 a - b, to desirously refract light about the luminaire 100 (shown in FIG. 1 ). [0048] Referring now to FIG. 6 , the upper structure 600 of an embodiment of the present invention is depicted. The upper structure 600 may include a body member 602 having an outer surface 604 . The outer surface 604 may be configured to reflect light incident thereupon. The outer surface 604 may have a reflection coefficient of at least about 0.1, or about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9, or about 0.91, 0.92, 0.93, 0.94, 0.95, 0.96, 0.97, 0.98, or 0.99, or about 1. In one embodiment, the outer surface 604 may act as a substrate and may have a layer of reflective paint applied thereto. In another embodiment, the outer surface 604 may have a reflective liner applied thereto. [0049] The upper structure 600 may further include a ridge 606 . The ridge 606 may interface with the prismatic optic 300 , thereby constraining the prismatic optic 300 between the upper structure 600 and the lower structure 200 . Furthermore, the ridge 606 may include one or more attachment surfaces 608 configured to facilitate attachment of the upper structure 600 to the prismatic optic 300 , as shown in FIG. 3 . The protruding members 326 of the upper optic 310 may be attached to the attachment sections 608 by any method that can withstand the forces experienced by the luminaire 100 , such as those experienced during installation and removal. Methods of attachment include, but are not limited to, adhesives, glues, welding, and fasteners. [0050] The upper structure 600 may further include one or more channels 610 formed in the outer surface 604 . The channels 610 may be configured to align with the attachment sections 608 , permitting the passage of protruding members 326 therethrough and facilitating the attachment of the prismatic optic 300 to the upper structure 600 . [0051] In the present embodiment, the upper structure 600 may be configured to act as a heat sink. Accordingly, portions of the upper structure 600 may be formed of thermally conductive material. Moreover, portions of the upper structure 600 may include fins 612 . In the illustrated embodiment, the fins 612 are configured to extend from the ridge 606 generally upwards and towards a longitudinal axis of the upper structure 600 . The fins 612 advantageously increase the surface area of the upper structure 600 and permit fluid flow between each fin 612 , enhancing the cooling capability of the lower structure 600 . The fins 612 may have a curved vertical profile to emulate the shape of traditional incandescent light bulbs. Optionally, the fins 612 may be configured to conform to the A19 light bulb standard size. Those skilled in the art will appreciate that the present invention contemplates the use of various configurations of fins to enhance heat dissipation. [0052] Referring now additionally to FIG. 7 , the body member 604 may further include an inner surface 614 defining an internal cavity 616 . The internal cavity 616 may be configured to cooperate with the longitudinal cavity 208 of the lower structure 200 , defining a continuous cavity. Furthermore, the body member 602 may include a shelf 617 extending radially inward from the inner surface 614 into the internal cavity 616 . [0053] As also illustrated in FIGS. 6-7 , the upper structure 600 may further include a recessed section 618 on the top of the upper structure 600 . The recessed section 618 may include an upper attachment section 620 . The upper attachment section 620 may be configured to attach a housing 900 (described below and illustrated in FIG. 9 ) thereto. The circuit board will be described in greater detail hereinbelow. The attachment section 620 may be configured to permit attachment by any method known in the art, including, but not limited to, fasteners, such as screw and threads, adhesives, glues, and welding. The upper structure 600 may further include a recessed region 622 formed in a lower surface of the body member 604 . The recessed region 622 may be positioned so as to approximately align with the recessed region 220 of the lower structure 200 . Alternatively, the upper structure 600 may be formed as a substantially solid structure, not including the various structural aspects intended to increase the cooling capacity as described above. [0054] Referring now to FIG. 8 , according to an embodiment of the invention, a luminaire including a light source 800 is provided. The present embodiment of the light source 800 employs one or more light emitting elements 802 . The light emitting elements 802 may be disposed within the optical chamber 301 of the prismatic optic 300 , as depicted in FIG. 3 . [0055] The light emitting elements 802 may be oriented to emit light that is incident upon the prismatic surfaces 332 of the upper optic 310 as well as the prismatic surfaces 372 of the lower optic 350 , as depicted, for example, in FIG. 5 . Accordingly, the light emitting elements 802 may be configured to emit light generally radially outward as well as upwards and downwards from the luminaire 100 , as shown in FIG. 1 . [0056] According to the present embodiment of the invention, the light source 800 may include a platform 804 . The platform 804 may include an upper surface 806 , a lower surface 808 , and a void 809 , wherein each of the upper and lower surfaces 806 , 808 are generally flat and configured to permit attachment of the light emitting elements 802 thereto. For example, the light source 800 may include a channel 810 formed into one of the upper surface 806 and the lower surface 808 , or both. The channel 810 may be configured to form a region in the upper surface 806 into which the light emitting elements 802 may be there attached. [0057] The location of the channel 810 on the upper surface 806 may be selectively chosen. In the present embodiment, the channel 810 is formed generally about the periphery of the upper surface 806 , although the channel 810 may be formed in any part of the upper surface 806 . In some embodiments, a plurality of light emitting elements 802 may be distributed within the channel 810 . Each of the plurality of light emitting elements 802 may be selectively distributed, for example, they may be spaced at regular intervals. In an alternative example, the light emitting elements 802 may be clustered in groups. The configuration of the disposition of the light emitting elements 802 may be selected to achieve a desired lighting profile or outcome. [0058] The channel 810 may further include an attachment material disposed within the channel 810 . The attachment material may facilitate the attachment of the light emitting elements 802 within the channel 810 . Furthermore, the attachment material may facilitate the operation of the light emitting elements 802 . For example, where the light emitting elements 802 are LEDs, the attachment material may be formed of an electrically conductive material. Furthermore, the attachment material may be configured to include two or more electrical conduits that are isolated from each other, facilitating the operation of the light emitting elements 802 . [0059] The light source 800 may further comprise a communication section 812 formed adjacent the channel 810 . Accordingly, the communication section 812 may be formed in either of the upper surface 806 and the lower surface 808 , or both. The communication section 812 may contact the channel 810 . Furthermore, the communication section 812 may be formed of an electrically conductive material. Accordingly, the communication section 812 may be in electrically coupled to the channel 810 . [0060] The communication section 812 may include a first terminal 814 and a second terminal 816 . Each of the first and second terminals 814 , 816 may be formed of an electrically conductive material, may contact the channel 810 , and further may be electrically coupled to the channel 810 . Furthermore, where the channel 810 may include an attachment section including two or more isolated electrical conduits, the first terminal 814 may be in communication with a first electrical conduit of the attachment section, and the second terminal 816 may be in communication with a second electrical conduit of the attachment section. For example, and not by limitation, the first terminal 814 may be in communication with a power source conduit, and the second terminal may be in communication with a ground conduit. [0061] Still referring to FIG. 8 , the first and second terminals 814 , 816 may each include a pad 818 , 820 respectively. The pads 818 , 820 may be configured to facilitate attachment of an electrical communication medium thereto. For example, and not by limitation, the dimensions of the pads may be selectively chosen to permit a wire to be soldered thereto. The pads 818 , 820 may be disposed approximately adjacent to the void 809 . Moreover, the pads 818 , 820 may be positioned so as to approximately align with the recessed region 220 of the lower structure 200 and the recessed region 622 of the upper structure 600 . The void 809 may be disposed about approximately the center of the platform 804 . The void 809 may be positioned and dimensioned to approximately align with the longitudinal cavity 208 as shown in FIG. 1 and the internal cavity 616 as shown in FIG. 7 , defining a continuous cavity. [0062] Referring now to FIG. 9 a, a housing 900 according to an embodiment of the invention is presented. The housing 900 may be configured to be disposed substantially about a power source. The housing 900 may include a base section 910 and a monolithic section 950 . The base section 910 may be configured to attach the housing 900 to the base 110 as shown in FIG. 1 . Specifically, the base section 910 may include a body member 911 including plurality of threads 912 configured to cooperate with the threads 114 of the base 110 , wherein the threads 114 are functional on both an inside surface and an outside surface of the base 110 . Alternatively, the base section 910 may be attached to the base 110 by other methods, including, but not limited to, adhesives, glues, fasteners, and welding. [0063] The base section 910 may include an opening (not shown) at a first end 914 . The opening may be configured to have the shape and sufficient dimensions to permit a power source to pass therethrough. The base section 910 may further include a flange 916 extending radially outward from the body member 911 . The base section 910 may still further include a sidewall 918 extending approximately orthogonally from the flange 916 . In one embodiment, the sidewall 918 may be configured to interfere with the fins 214 of the lower structure 200 . In such an embodiment, the housing 900 may be disposed within the longitudinal cavity 208 of the lower structure 200 , and the interference between the sidewall 918 and the fins 214 restricts the translation of the housing 900 beyond the point of that interference. Further, the base section 910 may include one or more ribs 920 that may be attached to the sidewall 918 , the flange 916 , and the monolithic section 950 . [0064] The monolithic section 950 may be configured as a hollow, generally straight, substantially elongated structure. It may include a first end 952 and a second end 954 , with the first end 952 being adjacent the base section 910 and the second end 954 being substantially apart from the base section 910 . The monolithic section 950 may include one or more sidewalls 956 intermediate the first end 952 and the second end 954 , extending generally upward from the base section 910 . The sidewalls 956 may be attached and continuous, so as to define an internal cavity there between. The dimensions of the internal cavity may be sufficient to permit a power source to be at least partially disposed therein, as depicted in FIG. 9 b. [0065] At least one of the sidewalls 956 may include an opening 957 towards the second end 954 . The opening 957 may be configured to facilitate the electrical coupling between a power source and the light source, illustrated in FIG. 8 , and described in greater detail hereinbelow. [0066] At least one of the sidewalls 956 may include one or more vents 958 . The vents 958 may be positioned anywhere along the sidewall 956 . In the present embodiment, the vents 958 are positioned substantially toward the first end 952 . The positioning of the vents 958 , as well as their shape and dimensions, may be selected so as to facilitate the flow of air between the internal cavity defined by the sidewalls 956 and the area surrounding the housing 900 . In one embodiment of the invention, the flow of air may increase the cooling capability of the housing 900 , thereby reducing the operating temperature of a power source disposed within the internal cavity defined by the sidewalls 956 . For example, the vents 958 may be positioned adjacent those parts of a power source that generate the most heat, permitting the rapid transportation of air heated by the power source out of the housing 900 and to heat sinks, such as certain embodiments of the upper structure 200 and the lower structure 600 . [0067] The monolithic section 950 may further include an attachment section 960 located substantially towards the second end 954 . Referring now to FIG. 7 , the attachment section 960 may be configured to attach to the upper attachment section 620 of the upper structure 600 . The attachment section includes a receiving lumen 962 through which a fastener may be disposed and attached thereto. In the present embodiment, a fastener 624 is disposed through the upper receiving section 620 and into the receiving lumen 962 , attaching to the receiving lumen, thereby fixedly attaching the housing 900 to the upper structure 600 . However, alternative embodiments permit the attachment section 960 to attach to the upper attachment section 920 by any method known in the art, including, but not limited to, adhesives, glues, and welding. [0068] Referring now to FIG. 10 , according to an embodiment of the invention, a luminaire including a cap 700 is provided. The cap 700 is configured to cover the recessed section 618 of the upper structure 600 , as depicted in FIG. 7 . The cap 700 includes a domed section 702 and a plurality of tabs 704 extending generally downward and approximately perpendicular to the domed section 702 . One or more of the plurality of tabs 704 may include a catch 706 disposed on one end of the tab 704 . As shown in FIG. 7 , the catch 706 may engage with the shelf 617 of the upper structure 600 , thereby removably coupling the cap 700 to the upper structure 600 . [0069] Referring now to FIG. 11 , a power source according to an embodiment of the present invention is presented. In the present embodiment, the power source may include a circuit board 1000 . The circuit board 1000 may be configured to condition power to be used by the light emitting elements 802 of the light source 800 . Furthermore, the circuit board 1000 may have a first end 1002 and a second end 1004 , wherein the first end 1002 is positioned generally downward and toward the base 110 , and the second end 1004 is positioned generally upward and toward the upper structure 600 . The circuit board 1000 may be dimensioned to permit at least a portion of the circuit board 1000 to be disposed within the internal void of the housing 900 . [0070] The circuit board 1000 may include a first electrical contact 1010 . The first electrical contact may be positioned toward the first end 1002 of the circuit board 1000 . The first electrical contact 1010 may be configured to electrically couple with the electrical contact 111 of the base 110 , thereby enabling the first electrical contact 1010 to supply power to the circuit board 1000 . The circuit board 1000 may further include a second electrical contact 1020 . The second electrical contact 1020 may be positioned toward the second end 1004 of the circuit board 1000 . The second electrical contact 1020 may be configured to electrically couple with the pads 818 , 820 ( 820 not shown) of the light source 800 . The electrical coupling between the second electrical contact 1020 and the pads 818 , 820 enables the circuit board 1000 to deliver power to the light emitting elements 802 . [0071] In one embodiment, the electrical contact 111 conducts power from a light fixture that provides 120-volt alternating current (AC) power. Furthermore, in the embodiment, the light emitting elements 802 comprise LEDs requiring direct current (DC) power at, for instance, five volts. Accordingly, the circuit board 1000 may include circuitry for conditioning the 120-volt AC power to 5-volt DC power. [0072] In a further embodiment, the circuit board 1000 may include a microcontroller. The microcontroller may be programmed to control the delivery of electricity to the light source. The microcontroller may be programmed to, for instance, dim the light emitting elements 802 according to characteristics of the electricity supplied through the electrical contact 111 . [0073] Referring now to FIG. 11 , the light emitted from the light emitting elements 802 may cooperate with the prismatic surfaces 332 , 372 and the grooves 318 , 358 to refract the emitted light substantially about the luminaire 100 . The prismatic surfaces, 332 , 372 and the grooves 318 , 358 may be configured to selectively refract light within desired ranges about the luminaire 100 . Furthermore, the light may be refracted to maintain a uniform intensity within desired ranges about the luminaire 100 . [0074] It is understood that the angles referred to herein are measured according to a polar coordinate system, wherein the angles are measured from the positive Z-axis directed vertically. Moreover, the intensities referred to are in reference to an intensity of the light emitted by the luminaire 100 within a certain angle range. In the present embodiment of the invention, the reference intensity is an average intensity of light emitted within the range of angles between 0 degrees and 135 degrees. [0075] Turning now to FIG. 12 , a graph of ranges of light refraction is presented. Light may be refracted within a first range 1210 about the luminaire. The first range 1210 may include angles within a range between about 0 degrees to about 135 degrees. Furthermore, the light emitted within the first range 1210 may be within about 20%, 10%, 5%, or 1% of the average intensity. [0076] Light may also be refracted within a second range 1220 about the luminaire 100 . The second range 1220 may include angles within a range between about 135 to about 150 degrees. Furthermore, the light emitted within the second range 1220 may be within about 20%, 10%, 5%, or 1% of the average intensity. Light may also be refracted within a third range 1230 about the luminaire 100 . The third range 1230 may include angles within a range between about 150 degrees to about 180 degrees. Furthermore, the light emitted within the third range 1230 may be within about 20%, 10%, 5%, or 1% of the average intensity. [0077] Referring now to FIG. 13 , an alternative embodiment of the invention is presented. In FIG. 13 , a luminaire 1300 is presented having similar elements to that of the embodiments described hereinabove. Specifically, the luminaire 1300 may include a body member 1310 , an optic 1320 carried by the body member 1310 and defining an optical chamber (not shown), and a light source (not shown) carried by the body member 1310 and positioned within the optical chamber. In some embodiments, the optic 1320 may have a first surface (not shown) and a second surface 1322 . Similar to the embodiments described herein above, the first surface may be an inner surface of the optic 1320 . Additionally, the first surface may include a plurality of generally vertical segments and a plurality of generally horizontal segments. Furthermore, the second surface 1322 may be generally smooth, and have a curvature. In some embodiments the curvature may be generally concave. For example, and not by means of limitation, the curvature may be within the range from about X degrees to about Y degrees. The degree of curvature may be configured to distribute light about the optic 1320 in a desired distribution. Yet further, the optic 1320 may have an upper end, a lower end, and a center. The vertical segments may be generally longer towards each of the upper end and the lower end than toward the center. Additionally, the horizontal segments may be generally longer towards the center than towards the upper and lower ends. The vertical segments and the horizontal segments may similarly be configured to distribute light in a desired distribution. [0078] In some embodiments, the optic 1320 may include an upper optic 1324 and a lower optic 1326 . In such embodiments, each of the upper optic 1324 and the lower optic 1326 may include a first surface and a second surface, similar to the first surface and the second surface 1322 described herein above. Similarly, the first surface of each of the upper optic 1324 in the lower optic 1326 may include a plurality of generally vertical segments and a plurality of generally horizontal segments. Furthermore the second surface of each of the upper optic 1324 and the lower optic 1326 may be generally smooth and comprise a curvature. The curvature of the second surface of each of the upper optic 1324 and the lower optic 1326 may be generally concave. More specifically, the curvature of each of the upper optic 1324 in the lower optic 1326 maybe concave in the direction of a center of the optic 1320 , where the upper optic 1324 and the lower optic 1326 are adjacent each other. Additionally, the curvature may be within the range from about X degrees to about Y degrees. [0079] The remaining elements of the luminaire 1300 , including the body number 1310 and the light source, may be substantially as described in the previous embodiments hereinabove. [0080] Some of the illustrative aspects of the present invention may be advantageous in solving the problems herein described and other problems not discussed which are discoverable by a skilled artisan. [0081] While the above description contains much specificity, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of the presented embodiments thereof. Many other ramifications and variations are possible within the teachings of the various embodiments. While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. [0082] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given.
A luminaire with a prismatic optic permits the nearly uniform distribution of light about the luminaire. The prismatic optic permits the use of directional light sources, such as light emitting diodes, while maintaining the uniform light distribution. Furthermore, a concave shape of the optic further enables uniform light distribution. When light emitting diodes are used, the luminaire further includes a heat sink to maintain a desirable operational temperature without negatively affecting the light distribution properties of the luminaire.
5
FIELD The present application for patent relates to fluid and gas transfer equipment, and more particularly to adapters for connecting connectors to gas or fluid valves. BACKGROUND Gas and fluid transfer systems typically include valves and any number of connectors. The valves receive the gas or fluid from a sources and can either permit or block the flow of the gas or fluid to a destination. Where the valve permits the flow of gas/fluid, the gas/fluid is received by the connector. The connector and the valve connection is air tight, thereby preventing the release of gas/fluid. The air tight connection is achieved by threadably connecting the opening of the valve with one end of the connector. To make a threadable connection, the connector and valve must be appropriately sized for each other. Valves and connectors are usually manufactured, distributed, and sold separately from each other and in a variety of different sizes. Accordingly, combinations of valves and connectors of different sizes are incompatible. An adapter is used to establish a connection between valves and connectors of differing sizes. An adapter includes a first portion which is sized for and threadably receives the valve and a second portion which is sized for and threadably receives the connector. However, to connect a particular valve to a particular connector, the adapter must appropriately sized for both. As the variety of sizes of valves and connectors grows linearly (n), the number of types of adapters needed grows on an n{circumflex over ( )}2 basis. As the number of differently sized adapters grows, stocking and inventory problems arise as sellers must keep appropriate stock of each sized adapter. Accordingly, it would be advantageous if the number of adapters required to match each of a set of valves to each of a set of connectors could be reduced. SUMMARY The present invention is directed to an adapter capable of connecting plural sizes of valves to a connector. The adapter has an outer surface with a thread thereon for connection to the connector. The adapter also has a distal inner surface with a thread thereon to accept a first sized valve, and a proximate inner surface with a thread thereon to accept a valve of a second size. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1A a diagram of an adapter in accordance with the teachings of the present invention; FIG. 1B is a diagram of an overhead view of the adapter illustrated FIG. 1A; FIG. 2A is an illustration of a valve, seal, adapter, and a connector, connectable to form a first embodiment of the present invention; and FIG. 2B an illustration of a gas/fluid transport apparatus in accordance with a first embodiment of the present invention; FIG. 3A is an illustration of a valve, seal, adapter, and a connector, connectable to form a second embodiment of the present invention; and FIG. 3B is an illustration of a gas/fluid transport apparatus in accordance with a second embodiment of the present invention. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Referring now to FIG. 1A, there is illustrated a diagram of an adapter in accordance with the teachings and principals of the present invention. The adapter includes a hollow substantially cylindrical member 100 made of, for example, plastic or a non-ferrous metal, such as brass. The cylindrical member 100 includes an outer surface 105 with an outwardly extending thread 110 . The outer surface 105 is capable of receiving an appropriately sized connector by mating the thread 110 on the outer surface 105 with a thread on an inner surface of the connector. Referring now to FIG. 1B, there is illustrated an overhead view of the adapter illustrated in FIG. 1 A. The outer surface 105 can also include flat surfaces 107 a, 107 b to facilitate tightening or removing the adapter from the valve/connecting with a wrench or pliers. The cylindrical member 100 includes a first portion 100 a, a second portion 100 b, and a third portion 100 c. The first portion 100 a is hollow and substantially cylindrical with an outer diameter 115 , a first diameter 120 a, and a first inner surface 125 a. The second portion 100 b is hollow and substantially cylindrical with outer diameter 115 , a second diameter 120 b, and a second inner surface 125 b. The third portion 100 c is hollow and substantially cylindrical with outer diameter 115 , a proximate diameter 120 c, and third inner surface 125 c. The first diameter 120 a is smaller than the third diameter 120 c. The first portion 100 a includes a first thread 130 a about the first inner surface 125 a and having a diameter equal to the first diameter 120 a. The third portion 100 c includes a second thread 130 c about the third inner surface 125 c and having a diameter equal to the third diameter 120 c. The first portion 100 a, and third portion 100 c are each capable of receiving an appropriately sized valve by mating the first thread 130 a or second thread 130 c with a thread on an outer surface of the valve or connector. The adapter includes a seal 135 to facilitate an air tight connection between the adapter and valve received at either the first portion 100 a or third portion 100 c. The seal 135 can be made of a flexible material such as thermoplastic rubber, nitrile rubber, or etylene-propylene-compound diene rubber. The seal 135 is also hollow and substantially cylindrical with an outwardly skirt 135 a, an outwardly extending step 135 c, and an inverse skirt 135 d. The seal 135 has a diameter selected to be similar to the second diameter 120 b, while the skirt 135 a has a maximum diameter selected to be similar to the first diameter 120 a, and the step 135 c has a diameter selected to be similar to the third diameter 120 c. The seal 135 is disposed inside the cylindrical member 100 , such that the step 135 c is surrounded by the third portion 100 c and the skirt 135 a is surrounded by the first portion 100 a. The step 135 c and the base of the skirt 135 a preferably rest against opposite sides of the second region 100 b. When a valve is received by the third portion 100 c, the step 135 a is pressed against the side of the second portion 100 b, thereby forming an air tight seal. Referring now to FIG. 2, there is illustrated a block diagram of a gas/fluid transport apparatus configured in accordance with a first embodiment of the present invention. FIG. 2A illustrates a valve 205 , a seal 135 , an adapter 99 , and a connector 210 . FIG. 2B illustrates the gas/fluid transport apparatus formed by connecting the valve 205 , seal 135 , adapter 99 , and the connector 210 in accordance with the teachings of the present invention. The valve 205 receives gas/fluid transports through a first opening 215 and transports the gas/fluid through a second opening 220 . The transport of the gas/fluid is controlled by a gate 225 which either blocks or permits the flow of the gas/fluid by opening or closing a passage from the first opening 215 to the second opening 220 . The passage is opened or closed by rotating a faucet head 230 . The second opening 220 is surrounded by a substantially cylindrical region 235 which includes a thread thereon 240 . The cylindrical region 235 , depending on size, is connectable to the third inner surface 125 c by meting the thread 240 on the cylindrical region 235 with the second thread 130 c. Connection of the cylindrical region 235 of the valve 205 to the third inner surface causes the step 135 c of the seal 135 to be pressed onto one side of the second region 100 b, while the skirt 135 a is pressed into the first region 100 a. The connector 210 receives the gas/fluid through an opening 250 in a tube 255 and transports the gas/fluid to a destination, through the tube 255 . The tube 255 is attached to a tightening nut 260 with an internal thread 265 . The tightening nut 260 is connectable to the outer surface 105 by meting the thread 110 on the outer surface to the internal thread 265 . The tightening nut 260 includes therein a connector seal 270 . The connector seal 270 includes a ramp 275 with a rising edge facing the hose 255 . The connector seal 270 is sized such that the smallest diameter of the ramp 275 is smaller than the first diameter 120 a and largest diameter of the ramp is larger than the third diameter 120 c. When the tightening nut 260 is connected to the outer surface 105 , the ramp 275 is passed into and against the first region 100 a, thereby forming an airtight seal. Referring now to FIG. 3, there is illustrated a block diagram of a gas/fluid transport apparatus configured in accordance with a second embodiment of the present invention. FIG. 3A illustrates a valve 205 , a seal 135 , an adapter 99 , and a connector 210 . FIG. 3B illustrates the gas/fluid transport apparatus formed by connecting the valve 205 , seal 135 , adapter 99 , and the connector 210 in accordance with the teachings of the present invention. The substantially cylindrical region 235 , depending on size, is connectable to the first inner surface 125 a by meting the thread 240 on the cylindrical region 235 with the first thread 130 a. The tightening nut 260 is connectable to the outer surface 105 by meting the thread 110 on the outer surface to the internal thread 265 . Connection of the tightening nut 260 to the outer surface 105 causes the connector seal 270 to be pressed into and against the third region 100 c. Additionally, the falling edge of the ramp 275 is received by the inverse skirt 135 d causing the seal 135 to be pressed against the edge of the cylindrical region 235 , thereby forming an airtight seal. Although preferred embodiments of the present inventions have illustrated in the accompanying drawings and described in the foregoing detailed description, it will be understood that the inventions are not limited to the embodiments disclosed, but are capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims and equivalents thereof.
An adapter and associated apparatus for transferring gas/fluid are presented herein. The adapter is configured to connect valves and connectors of plural sizes to each other. The adapter includes an outer surface having an outer thread for connection to a tightening nut of the connector. The adapter also includes a first and second inner surfaces sized for different size valves.
5
BACKGROUND OF THE INVENTION 1. Field of the Invention. This invention relates generally to joint prostheses, and more particularly to a modular bearing component for an artificial joint and method of replacement thereof. 2. Description of the Prior Art. Numerous artificial joint devices have been developed. In such joints as the shoulder or hip, the artificial or prosthetic joint typically includes a bearing head and bearing socket which are pivotable or rotatable with respect to one another, and each connected to opposing bone structures. From time to time, deterioration, infection or patient growth will necessitate a change in the prosthetic joint structure, such as providing a different sized bearing head or replacing one or more components of the prosthetic joint. For this reason, modular prosthesis systems have also been developed. Modular prosthesis systems are broadly accepted in the field of total hip replacements, with virtually all major orthopedic manufacturers in the United States and abroad offering femoral stem components with interchangeable bearings secured to the stem component by a self-locking tapered arrangement ("Morse" taper). The basic design for such hip prosthesis systems is essentially identical, and consists of a male shank which is machined on the femoral stem and which has a diameter in the range of 0.500 inches, a length of approximately 0.400 to 0.700 inches, and an approximately three degree included angle taper on the diameter. Bearing components of different diameters are machined with an identical matching female taper and are assembled with the femoral stem by impaction. One example of such an arrangement is shown in Harris U.S. Pat. No. 4,406,023. Once a bearing component has been impacted onto a femoral stem, it is firmly secured thereto and requires considerable axial opposing forces to cause disassembly. Such modular prosthesis systems provide a number of advantages, including the requirement of lower femoral stem inventories associated with the use of different diameter bearing components for the same stem, and the adjustability of the effective length of the neck portion of a stem by changing the depth of the female taper of the bearing components. In addition, surgical exposure during revision or replacement surgery is improved by the bearing component being removable, and the bearing components themselves are easily changeable during such surgery. Essentially all of the modular hip prosthesis systems include a device or specific structural feature to facilitate removal of the bearing component from the femoral stem during such surgery. These devices or features provide a means for applying an axial opposing force to the inferior margin of the bearing component (typically adjacent the female taper thereon) and usually involve a wedge or similar device which is driven between the underside of the bearing component and a broad collar and/or similar surface of the femoral stem. While the use of modular bearing components connected via the Morse taper is widespread with respect to prosthetic hip systems, it has not yet gained acceptance in artificial shoulder joints. The functional anatomy of the shoulder differs greatly from the hip, due principally to the dramatically greater range of motion required for optimal shoulder function. Thus, while the extension of the modularity concept to a shoulder prosthesis (i.e., a prosthetic stem with interchangeable bearing components) seems advantageous, certain physical obstacles must be overcome. The following United States patents illustrate various schemes for prosthetic shoulder joints: ______________________________________U.S. Pat. No. Inventor Issue Date______________________________________3,815,157 Skorecki et al. 6/11/743,869,730 Skobel 3/11/754,030,143 Elloy et al. 6/21/774,040,131 Gristina 8/9/774,206,517 Pappas et al. 6/10/80______________________________________ Each of these arrangements presents a somewhat complex joint, which necessarily requires the removal of more adjacent bone structure than desired in order to accommodate the prosthesis joint. Amstutz et al. U.S. Pat. No. 4,261,062 shows a shoulder joint prosthesis which is much simpler in design and requires less bone removal, but does not provide a modular bearing component arrangement. Perhaps the main reason that modularity has not yet gained acceptance in prosthetic shoulder joint schemes is anatomical. The anatomy of the humerus does not include a lengthened neck extending between the humeral head and shaft. Unlike a femoral component, therefore, there is no "neck" on an anatomically designed humeral stem component. The provision for such a neck requires the removal of more bone from the humerus than desired, and in prior art integral humeral stem prostheses, the inferior margin of the bearing is preferably placed in direct proximity with the level of resection of the humerus. A humeral stem component fabricated with a typical small diameter male tapered shank (i.e., 0.500 inches) to accommodate a bearing component with a mating female taper bore would, when assembled, have an identical appearance to a conventionally integral humeral stem prosthesis. When implanted, however, the inferior margin of such a modular humeral bearing component would transfer forces directly to the resected humerus and not necessarily to the humeral stem component. The absence of compressive force maintained between the bearing and stem components would permit separation of those components and distal migration of the stem component, which of course would result in clinical failure. In addition, the close proximity of the inferior margin of the bearing component and humerus (with no exposed shoulder of the humeral stem component therebetween) means removal of the bearing component from frictional engagement with the humeral stem component requires the exertion of an opposing force directly between the inferior margin of the bearing component and the humerus itself, with the potential for damaging the humerus, an obviously undesirable consequence of using a modular humeral bearing. Three modular shoulder prosthesis systems are known, the "Fenlin Total Shoulder" by Zimmer, Inc., the "Bio-Modular Total Shoulder" by Biomet, Inc., and a third by Interedics Orthopedics. In the first two systems, a proximal disk-shaped flange is provided on the humeral stem component, with a male Morse taper shaft extending upwardly therefrom. In the Intermedics shoulder, the proximal flange is a portion of a disk, which extends anteriorly and posteriorly from the central Morse taper shaft. In all three systems, a solid metal bearing component with a female Morse taper on its marginal side is frictionally mounted onto the male Morse taper shaft. Removal of the bearing component from the humeral stem is accomplished by exerting a prying force between the marginal side of the bearing component and the proximal flange of the humeral stem component. To facilitate such prying, a slight gap is provided between the marginal side of the bearing component and the exposed surface of the flange. In earlier, one-piece humeral bearing implants, efforts have been made to be certain that all exposed margins of the bearing component are as smooth and rounded as possible, not only to effectuate a smooth rotation of the bearing component on the glenoid, but also because the various tendons of the shoulder, particularly the rotator cuff tendons, must ride directly across the surface of the bearing component. In a total shoulder replacement patient, the rotator cuff tendons are often attenuated and weakened, and the discontinuity caused by the gap between the marginal surface of the bearing component and the flat edges of the proximal flange in the "Fenlin," "Bio-Modular," and Intermedics shoulder systems is undesirable, because it may contribute to further weakening of the tendons. In addition, the bearing components for the "Fenlin," "Bio-Modular," and Intermedics shoulder systems are solid metal, and thus relatively heavy, which can be significant in the function of a limb suspended against gravity. SUMMARY OF THE INVENTION The present invention provides modular prosthetic joint components which are simple and efficient in design, and which functionally perform (from the patient's point of view) in the same manner as integral joint prostheses, while potentially being lighter in weight. In addition, the present invention provides a method of assembly and disassembly of prosthetic joint components which is not only easy to use, but requires no further resection of the bone or forcing against the bone during the separation process. The present invention, in both apparatus and method forms, relates particularly to the unique design for a bearing component in a modular prosthetic joint. In such a prosthetic joint, a stem component is provided with a tapered shaft at one end thereof. The unique bearing component of the present invention has a bore therein which frictionally mates with the tapered shaft for mounting the bearing component on the stem component. A portion of the bearing component which extends over the tapered shaft is formed of relatively thin material. An outer surface of the bearing component defines an annular shoulder portion adjacent and about the bore therein. Means are provided for engaging the annular shoulder portion, and further means associated therewith are provided for piercing through the relatively thin material at the apex of the dome of the bearing component to engage the tapered shaft and urge the bearing component away from the tapered shaft. Preferably, the engaging means comprises a puller body which has a plurality of leg portions adapted to engage the annular shoulder portion of the bearing head. The piercing means is movably mounted with respect to the puller body and aligned to move along a longitudinal axis defined by the tapered shaft into engagement with the relatively thin portion of the bearing component, through such material and into engagement with the outer end of the tapered shaft. In performing the method of the present invention for removing a bearing component from frictional engagement with its tapered shaft, a puller body is first aligned about the bearing component so that a lower portion of the puller body engages a lower shoulder surface of the bearing component in a plane generally normal to a longitudinal axis defined by the tapered shaft. Then, the central upper bearing surface of the bearing component is pierced with a rod member which is movable longitudinally with respect to the puller body. Finally, the rod member is further moved into engagement with the tapered shaft to force the puller body and bearing component engaged thereby axially off of the tapered shaft after overcoming the frictional engagement of the bearing component and the tapered shaft. After the now-pierced bearing component has been thus removed from the tapered shaft, the rod member is withdrawn therefrom and the pierced bearing component is discarded. A replacement bearing component can then be mounted on the tapered shaft by impaction to achieve a frictional engagement therebetween. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an anterior view of the modular prosthetic joint assembly of the present invention, with some parts broken away and shown in section. FIG. 2 is a view similar to FIG. 1, also showing the bearing head puller of the present invention aligned about a bearing head. FIG. 3 is a view similar to that of FIG. 2, with the bearing head puller in piercing engagement with the bearing head. FIG. 4 is a view similar to that of FIG. 2, with the bearing head puller in engagement with the stem. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1, a prosthetic shoulder joint 10 is shown schematically. While this description is directed primarily to prosthetic shoulder joints, it is contemplated that the prosthetic joint assembly of the present invention is suitable for application to other body joints as well. The prosthetic shoulder joint 10 includes an elongated stem component 12 and a ball or bearing component 14 which is offset and angled with respect to the central axis of the stem component 12. The bearing component 14 is generally spherical on an outer bearing surface 16 thereof, and that surface articulates with the glenoid fossa 18 of the normal scapula 24, or articulates with a prosthetic glenoid component which resurfaces the glenoid fossa 18 and is secured in the scapula 24. The stem component 12 is mounted within the humerus 22, so that just the bearing component 14 mounted thereon extends upwardly and outwardly from the humerus 22, in operable alignment with the glenoid fossa 18 when the prosthetic joint assembly 10 is assembled as seen in FIG. 1. The stem component 12 has n elongated body section 30 which is entirely embedded within the humerus 22. A tapered shaft 32 is affixed to or integral with the body section 30 of the stem component 12 at one end thereof. The tapered shaft 32 forms a Morse taper frustum defined about a central longitudinal axis thereof, and as such, the tapered shaft 32 has an end surface 36 at its outermost end and the side walls thereof are defined as angular surfaces 38, with the tapered shaft having a greater diameter adjacent the stem component 12 than at its end surface 36. Preferably, the tapered shaft 32 has a relatively low profile relative to an adjacent outer surface 40 of the humerus 22. The bearing component 14 defines a bearing head for the prosthetic joint assembly of the present invention, and has a mounting side 52 opposite its outer bearing surface 16. The bearing component 14 has a bore or opening 56 on its mounting side 52. The bore 56 is a female Morse taper with its side walls being defined by angular surfaces 58 which mate with the angular surfaces 38 of the tapered shaft 32. When the bearing component 14 is inserted (and impacted) onto the tapered shaft 32, the angular surfaces thereof mate in a very firm friction fit, and no additional fasteners are required between the bearing component 14 and stem component 12. The bearing component 14 is generally hollow, like a bell, and opens out through its bore 56 when not mounted on the stem component 12. When the bearing component 14 and stem component 12 are assembled as seen in FIG. 1, however, a central portion 62 of the outer bearing surface 16 extends over the outermost end of the tapered shaft 32, with the central portion 62 formed to be relatively thin in cross section. On its mounting side 52, the bearing component 14 has an annular shoulder portion 64 which extends around the bore 56. The shoulder portion 64 is closely spaced from the outer surface 40 of the humerus 22 when the bearing component 14 is mounted on the tapered shaft 32. While there is a slight gap between the shoulder portion 64 and the outer surface 40, all exposed surfaces of the prosthetic shoulder joint 10 are broadly rounded and smooth in order to resemble a healthy, natural humeral bearing as closely as possible and to minimize any interference with the shoulder's tendons and muscles. Although hollow (and thus lightweight relative to a solid bearing component), the bearing component 14 is formed from a material of sufficient strength to maintain its rigid structure during use while mated with the glenoid 18. A prosthetic joint assembly of bearing component 14 and stem component 12 (in the form seen in FIG. 1) bears no outward indication that it differs from prior art stem and ball components, whether integral or modular. Functionally, the stem and ball assembly of FIG. 1 (with respect to the socket component 18) is also identical to prior prosthetic joint devices. For disassembly of the bearing component 14 and stem component 12, however, the differences between the prosthetic joint components of the present invention and the prior art become quite distinct. In the present invention, a bearing head puller 70 is used to disengage the bearing component 14 from the tapered shaft 32 by overcoming the frictional engagement therebetween. The bearing head puller 70 is seen, in various stages of operation, in FIGS. 2-4. The head puller 70 includes a puller body 72 which has one or more leg portions 74 adapted to engage the shoulder portion 64 of the bearing component 14. Each leg portion 74 has an inwardly projecting foot 76 which is tapered to fit between the shoulder portion 64 of bearing component 14 and the closely spaced and converging outer surface 40 of humerus 22. The feet 76 engage the shoulder portion 64 of the bearing component 14 along a plane generally normal to the longitudinal axis of the tapered shaft 32. The leg portions 74 are spaced apart sufficient to permit the puller body 72 to be mounted about the bearing component 14, as seen in FIG. 2. Similarly, at some point the feet 76 are spaced apart a distance greater than the largest diameter of the tapered shaft 32 to allow sufficient room for alignment of the bearing head puller 70 about the bearing component 14. The puller body 72 has a central body section 78, which connects the leg portions 74 together and extends over the central portion 62 of the bearing outer surface 60 of the bearing component 14 when the puller body 72 is mounted about the bearing component 14 as seen in FIG. 2. A pointed rod 80 is mounted to the central body section 78 of the puller body 70 to move axially toward and away from the bearing component 14 along the longitudinal axis of the tapered shaft 32. The pointed rod 80 is mounted on a threaded rod 82, which is threadably mated with central body section 78. The threads are aligned such that turning of the threaded rod 82 in a first rotational direction with respect to the central body section 78 causes the pointed rod 80 to move toward the bearing component 14, as indicated by arrow 83 in FIG. 3. As seen in a comparison of FIGS. 2 and 3, a point 84 of the pointed rod 80 is thus moved into engagement with the central portion 62 of the bearing outer surface 16 of the bearing component 14. Continued turning of the threaded rod 82 forces the point 84 and pointed rod 80 into and through the central portion 62, allowing the point 84 and pointed rod 80 to pass into the hollow internal cavity of the bearing component 14. Further continued rotation of the threaded rod 82 causes the point 84 and pointed rod 80 to move into engagement with the end surface 36 of the tapered shaft 32. Still further continued rotation of the threaded rod 82 forces the point 84 of the pointed rod 80 to bear against the end surface 36 of the tapered shaft 32, and ultimately this bearing force overcomes the frictional engagement force between the angular surfaces 38 and 58 of the tapered shaft 32 and bearing component 14, respectively. At that point, the bearing component 14 separates from the tapered shaft 32 and the feet 76 engaging the shoulder portion 64 of the bearing component 14 urge the bearing component 14 away from the tapered shaft 32 in direction of arrow 85, as seen in FIG. 4. The bearing component 14 and bearing head puller 70 both move away from the tapered shaft 32 in the direction of arrow 85. Turning of the threaded rod is facilitated by a handle 86. Once disengaged from the tapered shaft 32, the bearing component 14 is completely lifted away from the tapered shaft 32 and can then be replaced by frictional engagement of a new bearing component on the tapered shaft 32. The bearing head puller 70 is reusable by rotating the threaded rod 82 in an opposite rotational direction to withdraw its pointed rod SO from the removed and deformed bearing component 14. The deformed bearing component is then discarded and the bearing head puller 70 is ready for reuse in removing another bearing component. In one embodiment of the invention, a prosthetic humeral bearing component is machined out of ASTM F-75 Co/Cr/Mo alloy to have an outer spherical radius of 1,000 inches on its bearing or upper side. Because the bearing diameters of prosthetic shoulder joints are much larger than those used in prosthetic hip joints, the Morse taper between the bearing component and stem component can also be larger. By so doing, the larger annular shoulder left on the lower side of the bearing component (about its bore) provides the equivalent of the collar often found on a femoral stem component and provides a means to transfer and distribute loads to the resected humerus. Preferably, the female tapered bore of the bearing component is approximately 1.250 inch diameter by 0.200 inches in length, machined into the lower mounting side (inferior margin) of the bearing component. The humeral bearing component is machined out within the tapered bore section to a concentric spherical radius of 0.920 inches, thus creating a hollow bearing with a dome wall thickness of 0.080 inches. A central portion of the inner dome wall is machined to a 0.970 inch spherical radius, resulting in a 0.500 inch diameter section at the apex of the dome wall having a wall thickness of 0.030 inches. In a preferred embodiment, a puller body has three leg portions, spaced apart 120 degrees, and the pointed rod is formed of hardened steel with a pointed cylindrical tip of 45 degree included angle. In this configuration, advancement of the pointed rod into engagement with a humeral bearing component initially flattens the central portion of the dome wall slightly, followed by clean piercing or puncturing of the dome wall. Once the dome wall has been penetrated, further advancement of the pointed rod brings it to bear against the humeral stem component, applies a distracting force thereto and through the leg portions of the puller body, pulls the bearing component away from the stem component. The torque required to be applied to the pointed rod is relatively small in order to accomplish the piercing and disengagement of the humeral bearing component from the humeral stem component. CONCLUSION The present invention provides a modular prosthetic joint assembly which allows for quick and easy removal of a prosthetic bearing component for replacement or repair. The unique design of the bearing component to be replaced and its accompanying puller device allow a bearing component to be withdrawn from its mounting stem without the application of distraction forces directly against the bone structure of the patient, and without further removal of bone to achieve a bearing surface against which the puller device can react. The bearing component is disfigured during the removal process and is not reusable, but rater designed to be discarded and replaced. Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
An improved modular prosthetic joint has a stem portion embedded in a bone with a removable bearing head frictionally mounted on the stem portion. The bearing head has a bore which mates with a tapered shaft of the stem portion. The bearing head has a generally thin wall defining its continuous and unbroken bearing outer surface, with a wall portion extending directly over the tapered shaft which is thinner than the remainder of the bearing head wall. A puller engages an annular shoulder of the bearing head to pierce through the thinner wall portion of the bearing head, engage the tapered shaft and urge the bearing head away from the tapered shaft. Thus, the bearing head is pierced and removed from its associated stem portion, and second replacement bearing head is then mountable on the tapered shaft by impaction.
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CROSS REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62/100,425, filed Jan. 6, 2015, the disclosure of which is incorporated herein by reference in its entirety. FIELD OF THE INVENTION The instant disclosure relates to methods of manufacturing capacitor structures, particularly manufacturing methods for double layer capacitors or super/ultra-capacitors with trenched electrodes and increased surface area. The trenched super/ultra-capacitors disclosed herein are useful, for example, in energy storage devices in power applications. BACKGROUND OF THE INVENTION Electrochemical double layer capacitor or super/ultra-capacitors have been known for many years but have been used sparsely in power applications. A standard electrochemical double layer capacitor or super/ultra-capacitor traditionally consists of two high surface area electrodes that are polarized with the use of an electrolytic acid. The capacitance (C) of plate capacitors can be calculated with equation C=(ε*A)/d, where ε is the permittivity of the capacitor material, A is the surface area of the electrode plate, and d is the distance between plates. The charges in a super/ultra-capacitor are held between two ionic charges (distance d) called the Helmholtz layer. Due to the very short distance d, typically less than 0.4 μm, a very high capacitance compared to conventional capacitors can be achieved using the Helmholtz layer. The characteristics of super/ultra-capacitors include very fast charge time and high instantaneous power bursts. Since a super/ultra-capacitor does not rely on an electrochemical reaction, it also does not suffer from a “memory effect” that is often seen in batteries. Therefore, super/ultra-capacitors can bridge the gap between conventional capacitor (high power/low energy) and electrochemical devices such as rechargeable batteries (low power/high energy). In addition, super/ultra-capacitors are often seen as a “green” alternative compared to traditional batteries. The lifetime of super/ultra-capacitors can run maintenance free for 10-15 years; thus replacing traditional batteries with super/ultra-capacitors can reduce hazardous chemical wastes. However, mass adoption has been slow for electrochemical double layer capacitors or super/ultra-capacitors due to their low energy storage capacity compared to rechargeable batteries and relatively high cost for manufacturing. Applications of super/ultra-capacitors are limited mostly to industrial applications, such as regenerative braking for large trains or engine start for large commercial diesel trucks. There remains a need for electrochemical double layer capacitors or super/ultra-capacitors with higher energy storage capacity and low cost manufacturing processes in order to meet the increasing demand for fast charging and high capacity energy storage devices in today's emerging electronic applications like mobile phones and electric vehicles. BRIEF SUMMARY OF THE INVENTION The invention provides low cost processes and methods for making electrochemical double layer super/ultra-capacitors with trenched electrodes which provide high surface area and thus high energy storage capacity. In one aspect, provided is a method/process for making an electrochemical double layer capacitor comprising: producing a first trenched electrode by forming an electrode layer on a first substrate having a first trench opening therein; producing a second trenched electrode by forming an electrode layer on a second substrate having a second trench opening therein, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; combining the first trenched electrode with the second trenched electrode such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and filling the gap between the first and second trenched electrode with an electrolyte. In some embodiments, the process further comprises forming the first trench opening in the first substrate and forming the second trench opening in the second substrate. In some embodiments, the process comprises forming the trench openings by photolithography etching. In some embodiments, the first and/or second substrate is a highly doped silicon substrate, and forming the electrode layer on the first and/or second substrate comprises wet-etching a layer of the highly doped silicon substrate to form a porous silicon electrode layer. In some embodiments, the process further comprises forming (e.g., sputtering) a metal barrier layer on the first and/or second substrate prior to forming the electrode layer on the first and/or the second substrate, and forming the electrode layer on the first and/or second substrate comprises sputtering an electrode material on the metal barrier layer. In some embodiments, the metal barrier layer comprises Ti or TiN. In some embodiments, the electrode material is polypyrrole (PPY), activated carbon, graphene or carbon nanotubes. In some embodiments, the electrolyte is electrolytic acid, KOH/acetonitrile, or a gel electrolyte. In some embodiments, the substrates are highly doped silicon substrate. In some embodiments, the trench opening in the first trenched electrode and the protruding structure in the second trenched electrode are cylindrical in shape. In another aspect, provided is a die-saw process for making an electrochemical double layer capacitor comprising: providing a conductive plate, wherein the conductive plate is attached to an insulating substrate board via a non-conductive adhesive layer and is fitted with contact pads on both edges; forming a plurality of trenches by sawing the conductive plate at a predetermined pitch size to a depth where the adhesive layer is exposed, wherein the trenches having a floor composed of the non-conductive adhesive layer and side walls composed of the conductive plate; coating the floor and the side walls of the trenches with a layer of electrode material to form electrodes; sawing through the layer of electrode material on the floor of the trenches to form narrow trenches; inserting separators into the narrow trenches, wherein the separators are attached to a frame comprising side walls; sealing the sidewalls and the trench floor by flowing a framing adhesive around the separators; and injecting electrolyte to fill gaps between the electrodes and the separators. In some embodiments, the process further comprises placing the non-conductive adhesive layer on the insulating substrate board and attaching the conductive plate onto the non-conductive adhesive layer. In some embodiments, the process further comprises: injecting an adhesive to seal the topside; exposing the contact pads; attaching polar metal bars to the contact pads; and assembling into casing. In some embodiments, the insulating substrate board is marked with alignment marks. In some embodiments, the non-conductive adhesive is a wax or a glue. In some embodiments, the conductive plate comprises highly doped silicon. In some embodiments, the layer of electrode material comprises metal nano structure layer and a conductive metal oxide layer. In some embodiments, the electrode material comprises activated carbon, graphene, carbon nanotubes, or PPY. In some embodiments, the electrolyte comprising sulfuric acid or KOH/acetonitrile. Also provided is an electrochemical double layer capacitor produced by any of the processes described herein. Further provided is an electrochemical double layer capacitor assembly comprising one or more of the double layer capacitors produced by any of the processes described herein. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic top down view of an exemplary design of a trenched electrode. FIGS. 2-4 are schematic illustrations of another exemplary design of the trenched electrodes in a double layer super/ultra-capacitor. FIGS. 5-12 are schematic vertical cross-sectional views of exemplary embodiments in a wafer manufacturing process of making a double layer super/ultra-capacitor. FIGS. 13-22 are schematic vertical cross-sectional views of exemplary embodiments in a die-saw process of making a double layer super/ultra-capacitor. FIGS. 23-29 are schematic 3-dimensional views of exemplary embodiments in a die-saw process of making a double layer super/ultra-capacitor. DETAILED DESCRIPTION OF THE INVENTION The amount of charge that can be held in an electrochemical double layer capacitor or a super/ultra-capacitor is based on the total surface area of the electrodes. The electrodes are key parts for super capacitors. An increase in the surface area of the electrodes allows for more charge storage. Porous materials, typically carbon based materials have been used to achieve such goal. On top of the electrode is a current collector material to conduct the current. While research has been conducted to increase the surface area of the electrode by introducing more porous material such as graphene or nanotubes, the electrode surface area for a given material may be increased further by changing the topology of the current collector material. The present invention focuses on increasing the surface area of the electrodes to increase both power density and energy storage capacity of the super/ultra-capacitors. Thus provided are compositions for electrochemical double layer super/ultra-capacitors comprising electrodes having a three-dimensional trench topology rather than a standard planar topology. The trench structure creates extra planes at the trench side walls which increase the surface area of the current collecting material. When the electrode material is formed on top of this current collecting layer, a significant increase in surface area is achieved by tuning the trench parameters. The super/ultra-capacitor having trenches in the current collector material possesses a higher energy storage capacity combined with a higher power density compared to standard conventional planar super/ultra-capacitors. Referring to the drawings, FIG. 1 shows an exemplary design of an electrode having a three-dimensional trench topology. The dotted area is defined as the planar control area, whereas the total surface area is equal to (2*td+s+w)*(tc+m) and the proposed trench design area is defined as the control area+(2*tc+2*m+4td)*D, whereas, D is defined as the depth of the trench. The maximum difference between the planar and trench total surface area is achieved when D is set at maximum while s, w, tc and m are set as minimum. In one embodiment, the distance D is in the range of about 10 to about 500 μm. Furthermore, a higher degree of difference in surface area can be achieved using a cylindrical trench design. FIGS. 2-4 illustrate an exemplary design of an electrode having cylindrical trench openings. FIG. 3 shows horizontal cross-sectional views of a planar control area (without any trenches) and the circular openings in Structure 1 and Structure 2 . As defined as the planar control area, the total surface area is equal to L*W. With a cylindrical trench design, the total surface area for Structure 1 is equal to the control area+(L/1.5d)*(W/1.5d)*π*d*D, whereas D is the depth of the trench. The ratio between the total surface area in a cylindrical trench design and the total surface area of a standard planar design is 1+πD/(2.25d), or about 1+1.4*(D/d), whereas, D/d is the aspect ratio of the cylindrical trench design. For example, the total surface area of an electrode having a cylindrical trench design with an aspect ratio (D/d) of about 71 would be about 100 times of the surface area of a standard planar design. Using current state of the art deep trench etching methods, the D/d aspect ratio can be processed up to about 200, which would lead to about 280 times as much surface area relative to a standard planar design. Also provided are methods/processes for making the trenched double layer super/ultra-capacitors. The methods/processes take advantage of the better manufacturability of the trenched super/ultra-capacitors and employ techniques developed for semiconductor manufacturing such as a wafer manufacturing process and a die-saw process. The processes provides for increased scalability and reliability of the trenched electrodes. The term “a” or “an” as used herein, unless clearly indicated otherwise, refers to one or more. Manufacturing Process Using Photolithography Etching In one aspect, provided is a process for making an electrochemical double layer capacitor comprising filling a gap between a first trenched electrode and a second trenched electrode in an electrochemical double layer capacitor with an electrolyte, wherein the gap is formed by combining the first trenched electrode and the second trenched electrode to form the electrochemical double layer capacitor, wherein the first trenched electrode comprising a first trench opening, the second trenched electrode comprising a second trench opening having a 3-dimensional shape complimentary to the first trench opening in the first trenched electrode and a remaining protruding structure substantially the same in shape as the first trench opening in the first trenched electrode, wherein the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving the gap between the first electrode and the second electrode. In one aspect, provided is a process of making an electrochemical double layer capacitor comprising: (1) combining a first trenched electrode and a second trenched electrode to form an electrochemical double layer capacitor, wherein the first trenched electrode comprising a first trench opening, the second trenched electrode comprising a second trench opening having a 3-dimensional shape complimentary to the first trench opening in the first trenched electrode and a remaining protruding structure substantially the same in shape as the first trench opening in the first trenched electrode, wherein the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and (2) filling the gap between the first trenched electrode and the second trenched electrode with an electrolyte. FIG. 4 is an exemplary illustration of combining two trenched electrodes (Structure 1 and Structure 2 ) to form an exemplary double layer capacitor. The first trenched electrode (Structure 2 ) contains cylindrical trench openings in a silicon substrate; and the second trenched electrode (Structure 1 ) contains a trench opening in a silicon substrate having a 3-dimensional shape complimentary to the cylindrical trench openings in the first trenched electrode. The remaining protruding cylindrical structures in the second trenched electrode (Structure 1 ) are substantially the same in shape as the cylindrical trenches in the first trenched electrode (Structure 2 ); but the protruding cylinders in Structure 1 have a diameter that is smaller than the diameter of the cylindrical trenches in Structure 2 ( FIG. 2 ). The two trenched electrodes are combined by inserting the protruding cylinders in Structure 1 into the cylindrical trenches in Structure 2 . The structures are aligned to leave a gap between the opposing surfaces of the two electrodes (no direct contact between the two electrodes). The gap is then filed with an electrolyte to form the electrochemical double layer capacitor. In some embodiments, the process further comprises: (a) forming a first trench opening in a first substrate; (b) forming an electrode layer on the first substrate having the first trench opening therein, thereby producing the first trenched electrode; (c) forming a second trench opening in a second substrate, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; and (d) forming an electrode layer on the second substrate having the second trench opening therein, thereby producing the second trenched electrode. Referring to the figures, FIGS. 5 and 6 illustrate an exemplary process of forming trench openings in a substrate by a photolithography etching process. Specifically, as shown in FIG. 5 , a highly doped Si substrate ( 110 ) is used as the starting material. An optional isolation layer ( 115 ) such as SiO 2 is applied through chemical vapor deposition (CVD) or thermal oxidation on the starting substrate material. Photoresist ( 120 ) is spin on the doped Si substrate and then exposed using a photolithography mask. As shown in FIG. 6 , a trench is defined using a photolithography step by etch, or by removing the portion of silicon to create a Si ( 110 ) deep trench etch. Further, the photoresist ( 20 ) is then stripped off. In one embodiment, the trench depth is in the range of about 25 μm to about 75 μm deep. Any substrate suitable for making a double layer capacitor can be used for the first substrate and/or the second substrate, for example, highly doped silicon, in either heavily doped P Type silicon or heavily doped N Type silicon. Alternatively, the starting substrate material layer can include other semiconductor material such as, but not limited to, germanium, gallium nitride, gallium arsenide, silicon carbide, amorphous silicon, and a combination of single and polycrystalline silicon. In some embodiments, the first substrate and the second substrate are highly doped silicon substrate. The trench openings may be formed by methods developed for semiconductor manufacturing such as photolithography techniques. For example, an optional isolation layer such as SiO 2 is applied through chemical vapor deposition (CVD) or thermal oxidation on the starting substrate material. Photoresist with thickness of 1 μm to 3 μm is spun over the isolation layer. A lithographic pattern of the trench design is then exposed and developed over a mask layer before etching. In one embodiment, the trench pattern is then etched using an anisotropic plasma dry etching process. In some embodiments, the process comprises forming the trench openings in the substrate by photolithography etching. In some embodiments, the process comprises forming the first trench openings in the first substrate by photolithography etching. In some embodiments, the process comprises forming the second trench openings in the second substrate by photolithography etching. The trench openings in the trenched electrodes may be a contiguous trench formed in the substrate or a plurality of individual trenches. In some embodiments, the trench opening is cylindrical in shape (e.g., Structure 2 in FIG. 2 ). In some embodiments, the trench opening is a contiguous trench and a remaining protruding structure is cylindrical in shape (e.g., Structure 1 in FIG. 2 ). In some embodiments, the first trench opening in the first substrate is cylindrical in shape having a first diameter and the protruding structure in the second substrate is cylindrical in shape having a second diameter, and the second diameter is smaller than the first diameter. In some embodiments, the first diameter is 20% larger than the second diameter. In one embodiment, the first trench opening in the first substrate comprising a cylinder of about 1 μm in diameter and about 25 μm to about 75 μm in depth. In one embodiment, the first trench opening in the first substrate comprising a cylinder of about 1 μm in diameter and about 25 μm to about 75 μm in depth and the protruding structure in the second substrate comprising a cylinder of about 0.8 μm in diameter and about 25 μm to about 75 μm in depth. Such electrodes can be assembled to form a super/ultra-capacitor wherein the protruding cylinders (about 0.8 μm in diameter) in the second trenched electrode substantially fit into the cylindrical trenches (about 1 μm in diameter) in the first trenched electrode leaving a gap (about 0.1 μm) between the surface of the first electrode and surface of the second electrode. Alternatively, other shapes, such as a hexagon, ellipse, a polygon or a derivative of a rounded corner polygon can be used to serve as the same functional purpose as the cylinder. Once the trenches are formed in the substrate, an electrode material is then formed in the trenches to make the electrode layer. The electrode layer may be formed by converting a top layer of an appropriate substrate material into an electrode material, or by depositing a new layer of an electrode material on the surface of the substrate having the trench openings therein. In some embodiments, the electrode layer is formed on the substrate by converting a layer of the substrate material into an electrode material. In some embodiments, the substrate is a highly doped silicon substrate, and the process comprises forming an electrode layer on the first substrate having the first trench opening therein comprising wet-etching a layer of the highly doped silicon substrate to form a porous silicon electrode. In some embodiments, the process comprises forming an electrode layer on the second substrate having the second trench opening therein comprising wet-etching a layer of the highly doped silicon substrate to form a porous silicon electrode. In some embodiments, the electrode layer is formed on the substrate by depositing a layer of an electrode material on the surface of the substrate having the trench openings therein. In some embodiments, the process further comprises forming a metal barrier layer in the substrate with trench openings prior to forming the electrode layer. The electrode layer is then formed by sputtering an electrode material on the metal barrier layer. In some embodiments, the process comprises the steps of forming a metal barrier layer in the first substrate with the first trench opening and forming an electrode layer on the metal barrier layer by sputtering an electrode material on the metal barrier layer. In some embodiments, the process comprises the steps of forming a metal barrier layer in the second substrate with the second trench opening and forming an electrode layer on the metal barrier layer by sputtering an electrode material on the metal barrier layer. FIGS. 7 and 9 are illustrative diagrams showing an exemplary process of forming a metal barrier layer and then an electrode layer on a substrate having trench openings therein. FIG. 7 shows a metal barrier layer ( 130 ) formed on the substrate ( 110 ) having trench openings therein. FIG. 9 shows an electrode layer such as polypyrrole (PPY) ( 140 ) deposited along the metal barrier to form the electrode of the capacitor. Materials suitable for the metal barrier layer include, but are not limited to, Ti, TiN, Ni, NiAu, TiW, NiPdAu, TiS, Cr, Au, Pt and Pd. In some embodiments, the metal barrier uses a Ti or TiN material. Materials suitable for the electrode layer include, but are not limited to, polypyrrole (PPY), activated carbon, graphene or carbon nanotubes. The electrolyte (e.g., an electrolytic acid) between the electrodes is used to polarize the high surface area of the electrodes. The charges within the electrodes are held between two ionic charges (distance d) from the electrolyte (e.g., an electrolytic acid) creating the Helmholtz layer. The capacitance (C) of plate capacitors can be calculated with equation C=(ε*A)/d, where ε is the permittivity of the capacitor material, A is the surface area of the electrode plate, and d is the distance between the ionic charges. Due to the very short distance d, typically less than 0.4 μm, a very high capacitance compared to conventional capacitors can be achieved using the Helmholtz layer. Examples of electrolytes suitable for use in the electrochemical double layer capacitor of this invention include, but are not limited to, electrolytic acid, KOH/acetonitrile, a gel electrolyte. The shape and size of the trenches as well as the spacing between the individual trenches can be adjusted for the electrodes to ensure complimentary matching and control the size of the gap between the electrodes when combined into a double layer capacitor. In some embodiments, trenches are formed in a substrate (for example evenly spaced groves) such that the trenches and the remaining protruding structures are complimentary in shape. For example, an electrode shown in FIG. 9 has groves (trenches) and protrusions that are complementary in shape such that two of such electrodes can be combined as illustrated in FIG. 11 to form a capacitor as shown in FIG. 12 . In some embodiments of the process, the first electrode and the second electrode are combined and the gap between the electrodes is then filled with an electrolyte (such as an electrolytic acid). In some other embodiments of the process, the trenches in one of the electrodes may be filled with an electrolyte, and the other electrode is then inserted into the electrode having the electrolyte filled therein. Such process is especially useful in case when the electrolyte has poor fluidity (for example a gel electrolyte) and filling a narrow gap between two combined electrodes becomes difficult. In some embodiments, provided is a process of making an electrochemical double layer capacitor comprising the steps of: a) providing a first substrate; b) forming a first trench opening in the first substrate; c) optionally forming a metal barrier layer on the first substrate having the first trench opening therein; d) forming an electrode layer on the first substrate, thereby producing the first trenched electrode; e) providing a second substrate; f) forming a second trench opening in the second substrate, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; g) optionally forming a metal barrier layer on the second substrate having the second trench opening therein; h) forming an electrode layer on the second substrate, thereby producing the second trenched electrode; i) combining the first trenched electrode with the second trenched electrode such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and j) filling the gap between the first trenched electrode and second trenched electrode with an electrolyte (e.g., an electrolytic acid). In some embodiments, provided is a process of making an electrochemical double layer capacitor comprising the steps of: a) providing a first substrate (e.g., highly doped silicon); b) forming a first trench opening in the first substrate; c) forming a metal barrier layer (e.g., comprising a Ti or TiN) on the first substrate having the first trench opening therein; d) sputtering an electrode layer on the metal barrier layer on the first substrate, thereby producing the first trenched electrode; e) providing a second substrate (e.g., highly doped silicon); f) forming a second trench opening in the second substrate, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; g) forming a metal barrier layer (e.g., comprising a Ti or TiN) on the second substrate having the second trench opening therein; h) sputtering an electrode layer on the metal barrier layer on the second substrate, thereby producing the second trenched electrode; i) combining the first trenched electrode with the second trenched electrode such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and j) filling the gap between the first trenched electrode and second trenched electrode with an electrolyte (e.g., an electrolytic acid). In some embodiments, provided is a process of making an electrochemical double layer capacitor comprising the steps of: a) providing a first substrate, wherein the first substrate is a highly doped silicon substrate; b) forming a first trench opening in the first substrate; c) wet-etching a layer of the highly doped silicon on the first substrate to form a porous silicon electrode layer, thereby producing the first trenched electrode; d) providing a second substrate, wherein the second substrate is a highly doped silicon substrate; e) forming a second trench opening in the second substrate, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; f) wet-etching a layer of the highly doped silicon on the second substrate to form a porous silicon electrode layer, thereby producing the second trenched electrode; g) combining the first trenched electrode with the second trenched electrode such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and h) filling the gap between the first trenched electrode and second trenched electrode with an electrolyte (e.g., an electrolytic acid). In some instances, the trenches in a first trenched electrode is partially filled with an electrolyte, and a second trenched electrode is then combined by inserting the protruding structures of the second trenched electrode into the partially filled trenches in the first trenched electrode, forcing the electrolyte to fill the gap formed between the first and the second trenched electrodes. Thus, in some embodiments, provide is a method/process for making an electrochemical double layer capacitor comprising: a) producing a first trenched electrode by forming an electrode layer on a first substrate having a first trench opening therein; b) producing a second trenched electrode by forming an electrode layer on a second substrate having a second trench opening therein, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; c) partially filling the trench opening in the first trenched electrode with an electrolyte (e.g., a gel electrolyte); and d) combining the second trenched electrode with the first trenched electrode having the electrolyte partially filled therein, such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode. In some of these embodiments, the process further comprises forming the first trench opening in the first substrate and forming the second trench opening in the second substrate. In some of these embodiments, the process comprises forming the trench openings by photolithography etching. In some of these embodiments, the first and/or second substrate is a highly doped silicon substrate, and forming the electrode layer on the first and/or second substrate comprises wet-etching a layer of the highly doped silicon substrate to form a porous silicon electrode layer. In some of these embodiments, the process further comprises forming (e.g., sputtering) a metal barrier layer on the first and/or second substrate prior to forming the electrode layer on the first and/or the second substrate, and forming the electrode layer on the first and/or second substrate comprises sputtering an electrode material on the metal barrier layer. In some of these embodiments, the trench opening in the first trenched electrode and the protruding structure in the second trenched electrode are cylindrical in shape. In some of these embodiments, the trench opening (e.g., rectangular groves) in a trenched electrode and the protruding structure (e.g., rectangular protrusions) in the trenched electrode are complementary in shape. In some embodiments, provided is a process of making an electrochemical double layer capacitor comprising the steps of: a) forming a first trench opening in a first substrate; b) optionally forming a metal barrier layer on the first substrate having the first trench opening therein; c) forming an electrode layer on the first substrate, thereby producing the first trenched electrode; d) forming a second trench opening in a second substrate, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; e) optionally forming a metal barrier layer on the second substrate having the second trench opening therein; f) forming an electrode layer on the second substrate, thereby producing the second trenched electrode; g) partially filling the trench opening in the first trenched electrode with an electrolyte (e.g., a gel electrolyte); and h) combining the second trenched electrode with the first trenched electrode having the electrolyte partially filled therein, such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode filled with the electrolyte. Referring to the drawings, FIGS. 5-12 show schematics demonstrating an exemplary process of making a double layer super/ultra-capacitor using a wafer manufacturing process. FIGS. 5 and 6 are diagrams illustrating exemplary steps for forming a trenched opening in a substrate ( 110 ) by photolithography etching. FIGS. 7 and 9 are diagrams illustrating exemplary steps for forming a metal barrier layer ( 130 ) on a substrate having second trench openings therein and then forming an electrode layer ( 140 ) on the metal barrier layer. FIG. 10 is a diagram illustrating a trenched electrode having an electrolyte ( 150 ) (e.g., an electrolytic acid, solid state (gel) or liquid acid) is deposited into the trench region. FIG. 11 is a diagram illustrating combination of a trenched electrode having an electrolyte partially filled therein ( 170 ) and a trenched electrode having a complementary topology ( 160 ) to form an electrochemical double layer capacitor as illustrated by the diagram in FIG. 12 . In some embodiments, in order to complete a super/ultra-capacitor with packaging, the substrate (such as a silicon wafer) may be thinned to a desired thickness; one or more metal conductors may be deposited on the backside, which provide conductive contact points for connection with other devices, for example, a device for charging the super/ultra-capacitor or a device for drawing power from a charged super/ultra-capacitor. In some embodiments, in any of the process for making an electrochemical double layer capacitor described herein, the process further comprises back grinding the first substrate and the second substrate and depositing a conductive metal material. In some of these embodiments, the conductive metal material comprises a Ti—Ni—Ag tri-metal material. As shown in FIG. 8 , as desired by the final packaging type, the substrate wafer is thinned. Some silicon is removed to a thickness to fit the require package type. Metal is then deposited or plated on the backside. The metal system ( 132 ) will depend on the type of contact needed for the package type, e.g., solder or eutectic. In one embodiment, a tri-level metal system is used with Titanium, Nickel and Silver with a thickness of 2 k Angstroms, 3 k Angstroms and 10 k Angstroms, respectively. FIG. 12 shows an exemplary final structure with both electrodes, sealed as a single package device. In order to facilitate alignment of the two electrodes when they are combined to form the double layer capacitor, markings and tags can be used on the substrate. Thus in any of the embodiments of the process for making an electrochemical double layer capacitor described herein, the first substrate and the second substrate comprise set markings for alignment in the combining step. The double layer super/ultra-capacitor design illustrated in FIGS. 2-4 can be produced using a wafer process detailed herein. In one embodiment, referring to FIGS. 2-4 , the device is fabricated using the process as FIGS. 5-12 , but with using a cylindrical shape according to the following detail steps. As shown in FIG. 2 , a highly doped Silicon wafer is used with two complementary cylindrical trenches with a trench depth defined as D, and a trench width defined as d. In one embodiment, the trenched width is 1.2 d with a trench space of 0.5 d. As shown in FIG. 3 , in one embodiment, structure 1 as defined as having a trench space of 0.5 d, while structure 2 has a smaller trench space of 0.3 d and a large trench diameter of 1.2 d. In this embodiment, the space or gap allowed between the two electrodes is about 0.1 d when the two structures are assembled together. As shown in FIG. 4 , in one embodiment, structure 1 having the smaller trench diameter is inserted into structure 2 . Thus, in some embodiments, provided is a process of making an electrochemical double layer capacitor comprising the steps of: a) providing a first substrate; b) forming a cylindrical trench opening in the first substrate; c) optionally forming a metal barrier layer on the first substrate having the cylindrical trench opening therein; d) forming an electrode layer on the first substrate, thereby producing the first trenched electrode; e) providing a second substrate; f) forming a protruding cylindrical structure in the second substrate; g) optionally forming a metal barrier layer on the second substrate having the protruding cylindrical structure thereon; h) forming an electrode layer on the second substrate, thereby producing the second trenched electrode; i) combining the first trenched electrode with the second trenched electrode such that the protruding cylindrical structure in the second trenched electrode substantially fit into the cylindrical trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and j) filling the gap between the first trenched electrode and second trenched electrode with an electrolyte (e.g., an electrolytic acid). In some of these embodiments, the cylindrical trench opening in the first substrate comprises a cylinder of about 1 μm in diameter and about 25 μm to about 75 μm in depth. In some of these embodiments, the protruding cylindrical structure in the second substrate comprises a cylinder of about 0.8 ∞m in diameter and about 25 μm to about 75 μm in depth. In some of these embodiments, the cylindrical trench opening in the first trenched electrode comprises a cylinder of about 1 μm in diameter and about 25 μm to about 75 μm in depth, the protruding cylindrical structure in the second trenched electrode comprises a cylinder of about 1 μm in diameter and about 25 μm to about 75 μm in depth, and the gap between the surface of the first trenched electrode and the surface of the second trenched electrode is about 0.1 μm. Also provided is a double layer super/ultra-capacitor produced by a wafer manufacturing process (e.g., a photolithography etching process) detailed herein. Die-Saw Process In another aspect, provided is a die-saw process for making an electrochemical double layer capacitor, the process comprising the steps of: (1) providing a conductive plate, wherein the conductive plate is attached to an insulating substrate board via a non-conductive adhesive layer and is fitted with contact pads on both edges; (2) forming a plurality of trenches by sawing the conductive plate at a predetermined pitch size to a depth where the adhesive layer is exposed, wherein the trenches having a floor composed of the non-conductive adhesive layer and side walls composed of the conductive plate; (3) coating the floor and the side walls of the trenches with a layer of electrode material to form electrodes; (4) sawing through the layer of electrode material on the floor of the trenches to form narrow trenches; (5) inserting separators into the narrow trenches, wherein the separators are attached to a frame comprising side walls; (6) sealing the sidewalls and the trench floor by flowing a framing adhesive around the separators; and (7) injecting electrolyte to fill (partially or fully) gaps formed between the electrodes and the separators. In some embodiments, the process further comprises: (8) injecting an adhesive to seal the topside; (9) exposing the contact pads; (10) attaching polar metal bars to the contact pads; and (11) assembling into casing. In some embodiments, the insulating substrate board is marked with alignment marks. In some embodiments, the non-conductive adhesive is a wax or a glue. In some embodiments, the conductive plate comprises highly doped silicon. In some embodiments, the layer of electrode material comprises metal nano structure layer and a conductive metal oxide layer. In some embodiments, the electrode material comprises activated carbon, graphene, carbon nanotubes, or PPY. In some embodiments, the electrolyte comprising sulfuric acid or KOH/acetonitrile. Referring to the drawings, FIGS. 13-29 show schematics demonstrating an exemplary process of making a double layer super/ultra-capacitor using a die-saw manufacturing process. FIGS. 13-22 show lateral cross-sectional views of the devices in the process; while FIGS. 23-29 show exemplary 3-D diagrams. As shown in FIG. 13 , an insulating substrate board ( 200 ) is used as the starting material. The substrate board may have alignment marks ( 205 ) ( FIG. 23 ). A conductive plate ( 220 ) is then attached to the substrate board with an adhesive layer ( 210 ), e.g. wax or glue. A 3-D form of this structure is shown in FIG. 24 , where the conductive plate may be further fitted with two conductive stripes ( 225 ) on two opposing edges. In step (2), a plurality of trenches ( 240 ) is formed by sawing the conductive plate at a predetermined pitch size to a depth where the adhesive layer is exposed, wherein the trenches having a floor composed of the non-conductive adhesive layer and side walls composed of the conductive plate. As shown in FIG. 14 , a blade saw with a width of the determined pitch size is sawed through the conductive plate ( 220 ) and into the adhesive ( 210 ) creating a trench or trenches ( 240 ) in the conductive plate. In one embodiment, the trench width is about 5 to 30 μm. In step (3) the floor and the side walls of the trenches ( 240 ) are coated with a layer of electrode material ( 250 ) to form electrodes. In one embodiment, as shown in FIG. 15 , an electrode layer such as polypyrrole (PPY) ( 250 ) is deposited along the conductive plate and trench area to form the electrode of the capacitor. In step (4), narrow trenches ( 245 ) are formed in the floor of the trenches ( 240 ) sawing through the layer of electrode material on the floor of the trenches. As shown in FIG. 16 , a narrow blade is used for a die saw through the trench to separate the conductive layer for the separator to be inserted. In one embodiment, the narrow trench has a width of about 1 μm to about 5 μm. A 3-D form of this structure is shown on FIG. 25 . In step (5), separators ( 260 ) are inserted into the narrow trenches ( 245 ). The separators may be attached to a frame comprising side walls. In step (6), the sidewalls and the trench floor are sealed by flowing a framing adhesive around the separators. As shown in FIG. 17 , a separator ( 260 ) is inserted into the narrow trench along with a specifically designed frame to seal the both the sidewalls and the bottom frame. An adhesive, (e.g. glue or wax) is then used to reflow to seal both the sidewalls and bottom casing ( 270 ). A 3-D form of this structure is shown on FIG. 26 (also showing the frame with side walls). In step (7), an electrolyte ( 280 ) is injected into the remaining space in the trenches ( 240 ) to partially fill the gaps between the electrodes and the separators. As shown in FIG. 18 , an electrolytic acid, solid state (gel) or liquid acid ( 280 ) is deposited into the trench region between the electrodes and separators. In step (8), an adhesive is injected to seal the topside. As shown in FIG. 19 , an adhesive, (e.g. glue or wax) is then used to seal the top side of the casing ( 290 ). A 3-D form of this structure is shown on FIG. 27 . In the remaining steps (9)-(11), the contact pads are exposed; polar metal bars are attached to the contact pads; and the capacitor is assembled into casing. As shown in FIG. 20 , using a removal or etching tool, a trench is created to expose the contact area. In one embodiment, a hot air nozzle is used to expose the contact. A contact is then made to the metal using an ENIG Plating Ni/Au or NiPdAu bump ( 300 ) process ( FIG. 21 ). A final structure is shown in FIG. 22 with a solder bar used ( 310 ) for the contact and seal from the top with an epoxy material or wax. 3-D illustrations of this structure are shown in FIGS. 28 and 29 . In some embodiments, provided is a process of making an electrochemical double layer capacitor comprising the steps of: a) providing an insulating substrate board; b) placing a non-conductive adhesive (e.g., a wax or a glue) layer on the insulating substrate board; c) attaching a conductive plate (e.g., a highly doped silicon plate) onto the non-conductive adhesive layer, wherein the conductive plate is fitted with contact pads on both edges; d) forming a plurality of trenches by sawing the conductive plate at a predetermined pitch size to a depth where the adhesive layer is exposed, wherein the trenches having a floor composed of the non-conductive adhesive layer and side walls composed of the conductive plate; e) coating the floor and the side walls of the trenches with a layer of electrode material to form electrodes; f) sawing through the layer of electrode material on the floor of the trenches to form narrow trenches; g) inserting separators into the narrow trenches, wherein the separators are attached to a frame comprising side walls; h) sealing the sidewalls and the trench floor by flowing a framing adhesive (e.g., a glue or wax) around the separators; and i) injecting electrolyte to fill (partially or fully) gaps formed between the electrodes and the separators. In some embodiments, the die-saw process further comprises the steps of: j) injecting an adhesive to seal the topside; k) exposing the contact pads; l) attaching polar metal bars to the contact pads; and m) assembling into casing. In some embodiments, the process further comprises marking the insulating substrate board with alignment marks. In some of these embodiments, the layer of electrode material comprises metal nano structure layer and a conductive metal oxide layer. In some of these embodiments, the electrode material comprises activated carbon, graphene, carbon nanotubes, or PPY. Further provided is an electrochemical double layer super/ultra-capacitor produced by a die-saw manufacturing process detailed herein. The electrochemical double layer capacitors or super/ultra-capacitors detailed herein may be assembled together, for example, by connecting in series and/or in parallel to make a capacitor assembly. Thus provided is a double layer capacitor assembly comprising one or more of the double layer capacitors detailed herein and/or produced by a wafer manufacturing process and/or a die-saw manufacturing process detailed herein. EXEMPLARY EMBODIMENTS The invention is further described by the following embodiments. The features of each of the embodiments are combinable with any of the other embodiments where appropriate and practical. Embodiment 1 In one embodiment, the invention provides a process of making an electrochemical double layer capacitor comprising the steps of: a) producing a first trenched electrode by forming an electrode layer on a first substrate having a first trench opening therein; b) producing a second trenched electrode by forming an electrode layer on a second substrate having a second trench opening therein, wherein the second trench opening in the second substrate having a 3-dimensional shape complimentary to the first trench opening in the first substrate and a remaining protruding structure substantially the same in shape as the first trench opening in the first substrate; c) combining the first trenched electrode and the second trenched electrode such that the protruding structure in the second trenched electrode substantially fit into the trench opening in the first trenched electrode and leaving a gap between the first electrode and the second electrode; and d) filling the gap between the first trenched electrode and second trenched electrode with an electrolyte. Embodiment 2 In a further embodiment of embodiment 1, the process further comprises forming the first trench opening in the first substrate and forming the second trench opening in the second substrate. Embodiment 3 In a further embodiment of embodiment 2, the steps of forming the first trench opening in the first substrate and forming the second trench opening in the second substrate comprises photolithography etching. Embodiment 4 In a further embodiment of any one of embodiments 1 to 3, the first substrate and the second substrate are highly doped silicon substrate. Embodiment 5 In a further embodiment of embodiment 4, forming an electrode layer on the first and/or second substrate comprises wet-etching a layer of the highly doped silicon substrate to form a porous silicon electrode layer. Embodiment 6 In a further embodiment of any one of embodiments 1 to 4, the process further comprises forming a metal barrier layer on the first substrate prior to forming the electrode layer on the first substrate and/or forming a metal barrier layer on the second substrate prior to forming the electrode layer on the second substrate. Embodiment 7 In a further embodiment of embodiment 6, forming the electrode layer on the first substrate and/or forming the electrode layer on the second substrate comprises sputtering an electrode material on the metal barrier layer. Embodiment 8 In a further embodiment of embodiment 6 or 7, the metal barrier layer in the first substrate comprises Ti or TiN. Embodiment 9 In a further embodiment of any one of embodiments 6 to 8, the electrode material is polypyrrole (PPY), activated carbon, graphene or carbon nanotubes. Embodiment 10 In a further embodiment of any one of embodiments 1 to 9, the electrolyte is electrolytic acid, KOH/acetonitrile, or a gel electrolyte. Embodiment 11 In a further embodiment of any one of embodiments 1 to 10, the first trench opening in the first substrate is cylindrical in shape having a first diameter, the protruding structure in the second substrate is cylindrical in shape having a second diameter, and wherein the second diameter is smaller than the first diameter. Embodiment 12 In a further embodiment of embodiment 11, the first diameter is 20% larger than the second diameter. Embodiment 13 In a further embodiment of any one of embodiments 1 to 12, the first trench opening in the first substrate comprises a cylinder of about 1 μm in diameter and about 25 μm to about 75 μm in depth. Embodiment 14 In a further embodiment of any one of embodiments 1 to 13, the process further comprises back grinding the first substrate and the second substrate and depositing a conductive metal material. Embodiment 15 In a further embodiment of embodiment 14, the conductive metal material comprises a Ti—Ni—Ag tri-metal material. Embodiment 16 In a further embodiment of any one of embodiments 1 to 15, the first substrate and the second substrate comprise set markings for alignment in the combining step. Embodiment 17 In one embodiment, the invention provides an electrochemical double layer capacitor produced by a process according to any one of embodiments 1 to 16. Embodiment 18 In one embodiment, the invention provides a process of making an electrochemical double layer capacitor comprising the steps of: a) providing a conductive plate, wherein the conductive plate is attached to an insulating substrate board via a non-conductive adhesive layer and is fitted with contact pads on both edges; b) forming a plurality of trenches by sawing the conductive plate at a predetermined pitch size to a depth where the adhesive layer is exposed, wherein the trenches having a floor composed of the non-conductive adhesive layer and side walls composed of the conductive plate; c) coating the floor and the side walls of the trenches with a layer of electrode material to form electrodes; d) sawing through the layer of electrode material on the floor of the trenches to form narrow trenches; e) inserting separators into the narrow trenches, wherein the separators are attached to a frame comprising side walls; f) sealing the sidewalls and the trench floor by flowing a framing adhesive around the separators; and g) injecting electrolyte to fill gaps formed between the electrodes and the separators. Embodiment 19 In a further embodiment of embodiment 18, the process further comprises: h) placing the non-conductive adhesive layer on the insulating substrate board; and i) attaching the conductive plate onto the non-conductive adhesive layer. Embodiment 20 In a further embodiment of embodiment 19, the process further comprises: j) injecting an adhesive to seal the topside; k) exposing the contact pads; l) attaching polar metal bars to the contact pads; and m) assembling into casing. Embodiment 21 In a further embodiment of any one of embodiments 18 or 20, the insulating substrate board is marked with alignment marks. Embodiment 22 In a further embodiment of any one of embodiments 18 to 21, the non-conductive adhesive is a wax or a glue. Embodiment 23 In a further embodiment of any one of embodiments 18 to 22, the conductive plate comprises highly doped silicon. Embodiment 24 In a further embodiment of any one of embodiments 18 to 23, the layer of electrode material comprises a metal nano structure layer and a conductive metal oxide layer. Embodiment 25 In a further embodiment of embodiment 24, the electrode material comprises activated carbon, graphene, carbon nanotubes, or PPY. Embodiment 26 In a further embodiment of any one of embodiments 18 to 25, the electrolyte comprising sulfuric acid or KOH/acetonitrile. Embodiment 27 In one embodiment, the invention provides an electrochemical double layer capacitor produced by a process according to any one of embodiments 18 to 26. Embodiment 28 In one embodiment, the invention provides an electrochemical double layer capacitor assembly comprising one or more of the electrochemical double layer capacitors according to embodiment 27. All references throughout, such as publications, patents, patent applications and published patent applications, are incorporated herein by reference in their entireties. Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is apparent to those skilled in the art that certain minor changes and modifications will be practiced. Therefore, the description and examples should not be construed as limiting the scope of the invention.
A method of manufacturing trenched electrochemical double layer capacitors is provided. One aspect of the method employs state-of-the art processes used in semi-conductor wafer manufacturing such as photolithography etching for creating trenches in the electrodes of the double layer capacitor. Another aspect of the method employs a die-saw process, which is scalable and low-cost. The trenched super/ultra capacitors made by the disclosed methods have the combined advantage of higher energy storage capacity than conventional planar super/ultra capacitors due to the increased surface area and higher power density than commonly used Li-ion batteries due to the faster charging time and higher instantaneous energy burst power. The manufacturing processes also have the advantage of better manufacturability, scalability and reduced manufacturing cost.
8
CROSS REFERENCE TO RELATED APPLICATION [0001] This application is a divisional of U.S. patent application Ser. No. 09/804,026, filed Mar. 12, 2001, the entirety of which is hereby incorporated by reference. REFERENCE TO GOVERNMENT CONTRACT [0002] This invention was made with United States Government support under Contract No. DABT63-93-C-0025 awarded by the Advanced Research Projects Agency (ARPA). The United States Government has certain rights in this invention. FIELD OF THE INVENTION [0003] This invention relates generally to sealing flat panel displays, and more particularly, to cooling flat panel displays during a thermal sealing process. BACKGROUND OF THE INVENTION [0004] Cathode ray tube (CRT) displays are commonly used in display devices such as televisions and desktop computer screens. CRT displays operate as a result of a scanning electron beam from an electron gun striking phosphors resident on a distant screen, which in turn increase the energy level of the phosphors. When the phosphors return to their original energy level, they release photons that are transmitted through the display screen (normally glass), forming a visual image to a person looking at the screen. A colored CRT display utilizes an array of display pixels, where each individual display pixel includes a trio of color-generating phosphors. For example, each pixel is split into three colored parts, which alone or in combination create colors when activated. Exciting the appropriate colored phosphors thus create the color images. [0005] On the other hand, flat panel displays are becoming more popular in today's market. These displays are being used more frequently, particularly to display the information of computer systems and other devices. Typically, flat panel displays are lighter and utilize less power than conventional CRT display devices. [0006] There are different types of flat panel displays. One type of flat panel display is known as a field emission display (FED). FEDs are similar to CRT displays in that they use electrons to illuminate a cathodoluminescent screen. The electron gun is replaced with numerous (at least one per display pixel) emitter sites. When activated by a high voltage, the emitter sites release electrons, which strike the display screen's phosphor coating. As in CRT displays, the phosphor releases photons which are transmitted through the display screen (normally glass), displaying a visual image to a person looking at the screen. Each pixel can be formed by a trio of color-generating phosphors, each associated with a separate emitter. [0007] In order to obtain proper operation of the flat panel display, it is important for an FED to maintain an evacuated cavity between the emitter sites (acting as a cathode) and the display screen (acting as a corresponding anode). The typical FED is evacuated to a reduced atmospheric pressure of about 10 −6 Torr or less to allow electron emission. In addition, since there is a high voltage differential between the screen and the emitter sites, the reduced pressure is also required to prevent particles from shorting across the electrodes. [0008] Generally, the assembly of a flat panel display comprises a baseplate and a faceplate that are physically bonded together in forming a hermetic seal. For example, a glass powder, or frit, is placed in a continuous pattern along the outside perimeter of the display viewing area and melted at elevated temperatures to provide the desired hermetic seal. Typically, the cavity between the baseplate and faceplate is evacuated through an opening while a thermal cycle melts the frit. Once the display is sealed, it is generally important to uniformly cool the display assembly to minimize any thermal stress or shock that may result from immediate exposure to ambient temperature. [0009] To achieve uniform cooling of the display, however, using conventional methods such as conductive cooling takes long periods of time that can not be afforded in a manufacturing environment. Accordingly, there exists a need for a more rapid cooling process during high vacuum sealing of a flat panel display assembly. SUMMARY OF THE INVENTION [0010] These and other needs are satisfied by several aspects of the present invention. [0011] In accordance with one aspect of the invention, a method is provided for high vacuum sealing a flat panel display. The method includes lining the edges of a first component plate with a bonding material. A second component plate is positioned over the first component plate. The bonding material is thus sandwiched between the component plates, defining a cavity between the plates. The bonding material between the component plates is heated, followed by channeling a cooling fluid through the cavity. The cooling fluid has a lower temperature than the component plates. The cavity is thereafter evacuated. [0012] In accordance with another aspect of the present invention, a method for manufacturing a flat panel display. The method includes forming a flat panel display assembly with an internal cavity. The assembly is thermally processed in a processing chamber. After thermal processing, a first fluid flows through the cavity, cooling inner surfaces of the assembly by convection. Simultaneously, a second fluid flows within the processing chamber, cooling outer surfaces of the assembly by convection. The cavity can then be sealed. [0013] In accordance with another aspect of the invention, a method is provided for cooling a flat panel display assembly that includes at least two component plates. Cooling is conducted after melting a frit to bond the plates together and define a cavity between the plates. The cooling method includes simultaneously supplying heated gas to inside and outside surfaces of the flat panel display assembly while gradually cooling the gas. [0014] In accordance with another aspect of the present invention, a vacuum-sealed flat panel display is provided. The display includes a middle plate spaced between an upper plate and a lower plate. An upper cavity is thus defined above the middle plate, while a lower cavity is defined below the middle plate. In addition, a divider block extends between the middle plate and the rear plate. The block divides the lower cavity into two compartments, each of the which communicate with the upper cavity through at least one opening in the middle plate. BRIEF DESCRIPTION OF THE DRAWINGS [0015] These and further aspects of the invention will be readily apparent to those skilled in the art from the following description and the attached drawings, which are meant to illustrate and not to limit the invention, and wherein: [0016] [0016]FIG. 1 is a flow chart illustrating a method for high vacuum sealing a flat panel display in accordance with preferred embodiments of the present invention; [0017] [0017]FIG. 2A is a schematic cross-section of an unassembled flat panel display, constructed in accordance with a first embodiment of the present invention, including a faceplate and a baseplate; [0018] [0018]FIG. 2B illustrates a partially assembled flat panel display, with a bond material sandwiched between the baseplate and faceplate of FIG. 2A; [0019] [0019]FIG. 3 illustrates the flat panel display of FIG. 2B while cooling inside a furnace chamber; [0020] [0020]FIG. 4 illustrates the flat panel display of FIG. 3 following vacuum sealing; [0021] [0021]FIG. 5 is a schematic cross-section of an assembled flat panel display, constructed in accordance with a second embodiment of the present invention, including a backplate, baseplate and a faceplate with bonding material between the plates; [0022] [0022]FIG. 6 illustrates the flat panel display of FIG. 5 while cooling inside a furnace chamber; and [0023] [0023]FIG. 7 illustrates the flat panel display of FIG. 6 following vacuum sealing. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0024] It will be appreciated that, although the preferred embodiments are described with respect to FED devices, the methods taught herein are applicable to other flat panel display devices, such as liquid crystal displays (LCDs), organic light emitting devices (OLEDs), plasma displays, vacuum fluorescent displays (VFDs) and electroluminescent displays (ELDs). The skilled artisan will also readily appreciate that the materials and methods disclosed herein will have application in a number of other contexts where units are assembled and sealed at elevated temperatures. [0025] [0025]FIG. 1 is a flow chart exhibiting a preferred process for high vacuum sealing a flat panel display. As shown, the process begins with drilling 202 at least two holes or openings through a baseplate. The drilled holes preferably include holes proximate opposite edges of the baseplate, more preferably proximate diagonally opposite corners. In other arrangements it will be understood that holes can also be formed in the faceplate or a side surface of the display to be assembled. [0026] Following the drilling 202 of holes, a bond material is applied 204 in a pattern that will form a seal between the plates when assembled. The bond material, comprising a frit (glass powder) in the illustrated embodiments, is patterned around the edges of the faceplate, for example, by mixing the frit into a paste and then dispensing or screen printing the frit. In the preferred embodiment, the frit is preferably mixed into a paste and dispensed around the perimeter edges of the faceplate and/or backplate (see embodiment below), thus avoiding oxidation of the cathode on the baseplate while the frit is fired in air before assembly. The skilled artisan will readily appreciate that the bonding material can alternatively be applied to the baseplate (if oxidation of the cathode can be prevented) or to sidewalls on flanges extending from one of the baseplate and faceplate. [0027] Subsequently, the flat panel display is assembled 206 by aligning the faceplate over the baseplate to sandwich the bonding material between the faceplate and baseplate. The skilled artisan will appreciate that spacers maintain a uniform distance between the plates. As a result, a cavity is formed between the faceplate and the baseplate, which will allow the flat panel display to function. [0028] Following the assembly 206 of the flat panel display, a tube is affixed 207 to each of the drilled holes of the baseplate. The tubes can be affixed by using the same or similar frit that was used between the faceplate and baseplate. With the tubes affixed, the drilled holes can serve as input and output ports. [0029] The flat panel display assembly is placed 208 in a chamber, preferably a furnace chamber. The furnace chamber preferably comprises a first input opening and a first output opening to function as a chamber fluid dispenser and chamber fluid exhaust, respectively. [0030] The furnace chamber also preferably comprises a second input opening and second output opening. Preferably, the input and output ports of the flat panel display assembly are connected to communicate with the second input opening and the second output opening of the furnace chamber, thus forming input and output tubulation ports. [0031] After placing 208 and aligning the flat panel display assembly within the preferred furnace chamber, a vacuum is preferably applied to evacuate 210 the furnace chamber and the cavity between the faceplate and baseplate. The furnace chamber can be evacuated by any suitable means, such as conventional vacuum pumping. In this case the inside cavity of the flat panel display is preferably also evacuated, preferably by similar vacuum pumping means through the tubulation ports. [0032] In other arrangements, a reducing atmosphere (e.g., H 2 , CO, etc.) can be maintained within the flat panel display and/or in the furnace, minimizing the risk of oxidizing devices during subsequent thermal processing. [0033] After the furnace chamber and the flat panel display cavity are adequately evacuated 210 or filled with a reducing gas, the temperature within the furnace chamber is elevated high enough to melt 211 the frit sandwiched between the faceplate and the baseplate. The melted frit seals the inside flat panel display cavity from the outside environment. The skilled artisan will readily appreciate that other bonding processes may also require thermal or other energy input. [0034] Once the frit is melted 211 and the flat panel display assembly is sealed off, a cooling fluid is circulated 212 within the cavity, preferably by pumping fluid into the input tubulation port(s) through the cavity and out the output tubulation port(s). Preferably, the ports are arranged to achieve uniform convective cooling within the flat panel display assembly. The fluid, preferably a gas, also preferably comprises a non-oxidizing agent such as nitrogen, argon, etc., to protect the internal components of the flat panel display from oxidation. At the same time, to facilitate uniform cooling across the flat panel display assembly, cooling gas is also preferably circulated within the furnace chamber to provide controlled, convective cooling to the outside of the assembly. [0035] In the final hermetically sealed condition, the components of the flat panel display are subjected to a substantial amount of stress due to the pressure differential between the inside and the outside of the assembly. Accordingly, a similar pressure differential between the inside and outside of the flat panel display during the thermal cycle is most preferably applied. The pressure differential can be applied by evacuating the display after the frit has sealed the package and the temperature has somewhat reduced, such that the frit is solidified. Alternatively, the furnace can be pressurized during the thermal cycle prior to final evacuation of the display. This allows the components of the flat panel display to be subjected to stresses similar or equal to those that the assembly will be subjected to in the final sealed condition. In other words, this configuration allows for the flat panel display to be pre-stressed or conditioned during the sealing process. [0036] Following the cooling 212 of the flat panel display, the inside cavity is preferably evacuated 214 by vacuum pumping through the tubulation ports of the flat panel display. The input and output ports of the flat panel display are pinched off 215 to seal the inside cavity from the outside environment. Pinch-off heaters elevate the temperature of the evacuated input and output ports enough to collapse the ports and seal the openings. The vacuum-sealed flat panel display can then be removed 216 from the furnace chamber. [0037] The sealing process of the preferred embodiments will now be described in more detail with reference to FIGS. 2 - 7 . [0038] With reference initially to FIG. 2A, components of an unassembled flat panel display are shown. The main components of a flat panel display include a frontal support element or faceplate 10 and a rear support element or baseplate 20 , both which are preferably manufactured of a glass compound. In the illustrated FED embodiment, the baseplate 20 comprises cathode emitter tips while the faceplate includes an anode element and photo-luminescent coating, such as phosphors. [0039] At least two holes 12 a and 12 b are formed through the baseplate 20 . Tubes 16 a and 16 b are affixed therebelow by any suitable means, forming input and output ports to the interior of the assembly. While illustrated schematically with two holes 12 a , 12 b , the skilled artisan will appreciate that multiple holes can be peripherally positioned to obtain uniform flow from inlet ports to outlet ports across the inner surfaces of the flat panel display. Most preferably, two holes are positioned proximate diagonally opposite corners. [0040] Additionally, a bond material is preferably placed on the perimeter edges of the faceplate 10 . The preferred bond material is a frit 5 , comprising glass powder and other additives that, when mixed into a paste, is advantageously used to make a thermally compatible vacuum tight seal between two glass compounds. The frit 5 can be applied using conventional methods. [0041] After firing the frit 5 , the components of FIG. 2A are then assembled together to form the flat panel display assembly 30 , as shown in FIG. 2B. Spacers and alignment markers (not shown) aid in the assembly to produce a uniform space or cavity 18 between the plates. The frit 5 is sandwiched between the faceplate 10 and the baseplate 20 , forming a cavity 18 therebetween. [0042] Prior to or subsequent to the assembly of the flat panel display 30 , it is placed inside a chamber, preferably a furnace chamber 40 . With reference to FIG. 3, the furnace chamber 40 comprises at least one inlet 42 and at least one outlet 45 for fluid flow and/or evacuation of the chamber during the sealing process. The illustrated furnace chamber 40 further comprises a second input opening 47 and a second output opening 49 . The flat panel display 30 is aligned within the furnace chamber 40 so that the tubes 16 a , 16 b communicate with the second input opening 47 and second output opening 49 , respectively, thus forming an input tubulation port 61 and output tubulation port 62 . [0043] For some flat panel display technologies, it is advantageous for thermal processes (for example, to melt the frit as described below) to be conducted in a reducing atmosphere or vacuum to protect the components of the display from oxidation. In the preferred embodiment, once the flat panel display 30 is assembled and aligned within the furnace chamber 40 , both the chamber 40 and the cavity 18 are preferably evacuated by any suitable means. Using conventional vacuum pumping, the pressure range within the chamber 40 and the cavity 18 is pumped down to preferably between about 10 −9 Torr and 10 −5 Torr, more preferably between about 10 −8 Torr and 10 −6 Torr. During the pump-down (preferably over 2-3 hours) the chamber 40 temperature is preferably elevated to between about 300° C. and 350° C., more preferably between 320° C. and 330° C. to bake-out any moisture contained within the display package 30 . In other arrangements, the cavity 18 can be filled with reducing agents (e.g., H 2 , CO, etc.) rather than being evacuated. [0044] After both the chamber 40 and cavity 18 are adequately evacuated or filled with reducing gas, the temperature within the furnace chamber 40 is raised to a high enough temperature to melt the frit 5 sandwiched between the faceplate 10 and baseplate 20 . By melting the frit 5 , the faceplate 10 and the baseplate 20 are effectively bonded to one another, sealing the cavity 18 from the chamber 40 . To melt the frit, the temperature within the furnace chamber 40 is preferably elevated to between about 300° C. and 550° C., more preferably between about 400° C. and 500° C. for a preferred duration of between about 15 minutes and 30 minutes, more preferably between about 20 minutes and 25 minutes. [0045] Depending of the design of the flat panel display assembly, an external force can also be applied to the outside of the package assembly during the melting process to maintain alignment of the assembly and to help the frit 5 flow. The external force may be applied utilizing fixed clamps, springs clamps, weights, etc. [0046] Subsequent to thermal sealing of the flat panel display assembly 30 , it is generally advantageous to cool the flat panel display assembly 30 to minimize thermal shock resulting from ambient exposure. At the same time, in a manufacturing environment, it is generally desirable to expedite the cooling of the flat panel display assembly 30 to improve production throughput. [0047] Accordingly, an internal cooling fluid 65 is pumped into the input tubulation port 61 and out through the output tubulation port 62 to convectively cool the inside of the flat panel display 30 . The cooling fluid also preferably comprises a non-oxidizing agent such as nitrogen or argon, or a reducing agent such as H 2 or CO, protecting the internal components of the display from oxidation during the process. Preferably, the cooling fluid is initially heated to a temperature below that of the thermal process by between about 5° C. and 10° C., more preferably between about 10° C. and 20° C. The initial flow of gas is heated to minimize any thermal shock induced by the temperature difference between the flat panel display 30 and the cooling fluid. Band heaters (not shown) or any suitable means as is well known in the art can conduct heating of the cooling fluid. [0048] The cooling fluid 65 , comprising argon gas in the illustrated embodiment, is pumped initially at a rate preferably between about 25 sccm and 500 sccm, more preferably between 50 sccm and 100 sccm, at a preferably temperature range between about 300° C. and 500° C., more preferable between about 400° C. and 500° C. Thereafter, the temperature of the cooling gas 65 is decreased at a preferable rate to optimize convective cooling of the flat panel display 30 . Preferably, the temperature of the cooling gas 65 is decreased at a rate of between about 5° C./min and 30° C./min, more preferably between about 10° C./min and 20° C./min. Also, to further optimize convective cooling of the flat panel display 30 , it may be advantageous to increase the flow rate of the cooling gas 65 as its temperature is being decreased. In the preferred embodiment, the flow rate of the cooling gas 65 is increased preferably increased to between about 100 sccm and 1000 sccm, more preferably between about 250 sccm and 750 sccm. As an example, the flow rate of cooling gas 65 can be increased by between about 10 sccm/min to 20 sccm/min. The skilled artisan will readily appreciate that minimizing thermal shock can be achieved by either or both of controlling the cooling gas temperature and controlling the cooling gas flow rate. [0049] To insure that the cooling of the flat panel display 30 is uniform, it is advantageous to pump an external cooling gas 67 into the furnace chamber 40 to provide controlled, convective cooling to outside surfaces of the flat panel display 30 . A preferably inert or non-oxidizing gas, comprising argon in the illustrated embodiment, is pumped into the chamber fluid dispenser 42 at a rate preferably between about 25 sccm and 500 sccm, more preferably between about 50 sccm and 100 sccm. Also, the flow of the external gas 67 is preferably increased at a rate of between about 10 sccm/min and 20 sccm/min. Like the internal cooling gas 65 , the temperature of the external cooling gas 67 is constantly kept lower than the temperature of the cooling assembly 30 . Moreover, the external cooling gas 67 temperature is preferably the substantially same temperature as the internal cooling gas 65 , such that the substrates or plates are uniformly cooled from inside and out and thermal stress cracking is avoided during the aided cool down. Insubstantial differences in actual gas temperature between the internal cooling gas 65 and the external cooling gas 67 may result, for example, by differences in pathlengths from a common heat source to the inner and outer surface of the assembly 30 , respectively. [0050] As a result of exposure to cooling fluids 65 , 67 , the temperature of the flat panel display 30 is desirably brought down to between about 30° C. and 100° C., more preferably between about 30° C. and 50° C., after between about 2 and 3 hours. [0051] Subsequent to the cooling of the flat panel display 30 , the cavity 18 is evacuated through the tubulation ports 61 and 62 . Uniform evacuation can be aided by switching both ports to the vacuum source by means of conventional switch valves. Alternatively, a reducing agent (not shown) such as hydrogen (H 2 ), carbon monoxide (CO), etc., may be subsequently back-filled into the cavity 18 , particularly where inert cooling gas was employed prior to evacuation. Introducing H 2 , for example, before a final evacuation of the cavity 18 may be advantageous for the emitter tips (not shown) of the flat panel display 30 . [0052] With reference to FIG. 4, once the cavity 18 is evacuated of the cooling gas 65 and any reducing agent, the input and output ports 16 a , 16 b are pinched off or sealed to effectively seal the inside cavity 18 from the surrounding environment. Pinch-off heaters, or other sealing mechanisms as are well known in the art, are utilized to seal the input and output ports 16 a and 16 b . The pinch-off heaters, for example, elevate the temperature of the evacuated tube ports 16 a and 16 b high enough to collapse them and form seals 15 a and 15 b at the corresponding drilled holes ( 12 a , 12 b ). Once cooled, evacuated and sealed, the flat panel display 30 is removed from the furnace chamber 40 . [0053] In accordance with a second embodiment, FIG. 5 illustrates components of an unassembled flat panel display 130 comprising a frontal support or faceplate 110 , middle support or baseplate 120 and a rear support or backplate 125 . This three-piece configuration differs from the two-piece (i.e., faceplate and baseplate) configuration of FIGS. 2 - 4 in that the baseplate 120 is thinner than the faceplate 110 and an additional backplate 125 is provided. [0054] [0054]FIG. 5 further illustrates similar bond material or frits 105 a , 105 b at the perimeter edges of both the backplate 125 and the faceplate 110 , which are fired in air prior to assembly. During this firing, the baseplate 120 is not present, avoiding oxidation of the cathode. When assembled, as is illustrated in FIG. 5, the baseplate 120 is sandwiched between the faceplate 110 and the backplate 125 with frits 105 a , 105 b on both top and bottom of the baseplate 120 . The sandwiching of the three pieces forms a divided cavity, comprising an upper cavity 118 a and a lower cavity 118 b , between the faceplate 110 and backplate 125 . [0055] Holes 112 a , 112 b are drilled through the backplate 125 , with tubes affixed to form an input port 116 a and an output port 116 b . Additionally, a second set of at least two holes ( 112 c and 112 d ) are also drilled through the baseplate 120 , which will allow for fluid to be pumped through both sides of the baseplate 120 . The holes 112 a , 112 b through the backplate 125 are preferably centrally located, whereas the holes 112 c , 112 d in the baseplate 120 are preferably peripherally located, as will be better understood from the following discussion. [0056] A divider 135 is most preferably mounted to the interior side of the backplate 125 or baseplate 120 (shown on the backplate 125 ). This divider 135 preferably extends across one dimension of the assembly 130 . An additional frit 105 c is placed on one side of the divider 135 such that, when assembled, it is sandwiched between the baseplate 120 and the divider 135 and divides the lower cavity 118 b into two compartments. [0057] With reference to FIG. 6, an assembled flat panel display 130 is positioned within a furnace chamber 140 , wherein the input and output ports 116 a , 116 b correspondingly communicate with the second input and output openings 147 , 149 of the furnace chamber 140 . As a result, input and output tubulation ports 161 , 162 are thus formed. [0058] As mentioned above, for some flat panel display technologies, it is advantageous for thermal processes (for example, to melt the frit as described below) to be conducted in a reducing atmosphere or vacuum to protect the components of the display from oxidation. In the preferred embodiment, once the flat panel display 130 is mounted within the furnace chamber 140 , both the chamber 140 and the cavity 118 a , 118 b are accordingly evacuated by any suitable means. Using conventional vacuum pumping, the pressure range within the chamber 140 is preferably pumped down slowly to between about 10−9 Torr and 10 −5 Torr, more preferably between about 10 −8 Torr and 10 −6 Torr. The cavity 118 a , 118 b is preferably pumped down to the same pressure ranges. Desirably, the chamber 140 temperature is elevated to between about 300° C. and 350° C., more preferably between 320° C. and 330° C., during pump-down over 2-3 hours to bake-out any moisture contained within the display package 130 . [0059] Subsequently, the temperature within the furnace chamber 140 is raised to a high enough temperature to melt the frits 105 a , 105 b , 105 c sandwiched above and below the baseplate 120 . By melting the frits 105 a , 105 b and 105 c , the assembly components are effectively bonded to one another, sealing the cavity 118 a , 118 b from the chamber 140 . To melt the frits 105 a , 105 b and 105 c , the temperature within the furnace chamber 140 is preferably elevated to between about 300° C. and 550° C., more preferably between about 400° C. and 500° C. for a preferred duration of between about 15 minutes and 30 minutes, more preferably between about 20 minutes and 25 minutes. [0060] Subsequent to melting the frits 105 a , 105 b , 105 c at elevated temperatures, it is generally advantageous to cool the flat panel display 130 in a manner that minimizes thermal shock induced from ambient exposure. However, in a manufacturing environment, it is also generally desirable to expedite the cooling of the flat panel display 130 to improve production throughput. [0061] Accordingly, as shown in FIG. 6, cooling fluids 65 , 67 are provided to the interior and exterior of the assembly 130 to provide a uniform convective cooling to inside and outside surface of the flat panel display 130 . Preferred cooling gas compositions, temperatures and flow rates can be as described for the previous embodiment. [0062] Within the assembly 130 , cooling fluid 65 circulates both above and below the baseplate 120 through both portions 118 a , 118 b of the cavity by means of the two drilled holes 112 c , 112 d . As briefly noted above, the relative positions of the holes 112 a , 112 b and holes 112 c , 112 d , with respect to each other and to the divider 135 , are selected to optimize uniform distribution of the cooling gas 65 in both portions 118 a , 118 b of the cavity. In particular, the lower holes 112 a , 112 b are preferably positioned proximate the divider 135 , whereas the central holes 112 c , 112 d are preferably located peripherally. Thus, at least one of the lower holes 112 a , 112 b communicates with each of the compartments on either side of the divider 135 . Similarly, at least one of the central holes 112 c , 112 d communicates with each of the compartments on either side of the divider 135 . [0063] During the cooling process, once the frits have solidified enough to seal the inside of the display 130 from the outside, a pre-stressing pressure differential is established between the inside of the display 130 and the chamber 140 . The differential can be established by any combination of pressurizing and pumping down the display 130 and chamber 140 , but the differential should be equivalent to the final product pressure differential, e.g., about atmospheric in the chamber 140 and about 10 −6 Torr within the display 130 . [0064] Referring to FIG. 7, subsequent to cooling the flat panel display 130 , the cavity 118 a , 118 b is again evacuated through the tubulation ports 161 , 162 . Uniform evacuation can be aided by switching both ports to the vacuum source by means of conventional switch valves. The input and output ports 116 a , 116 b are then pinched off or sealed to effectively seal the inside cavity 118 a , 118 b from the surrounding environment, as described above, forming seals 115 a , 115 b at the drilled holes 112 a , 112 b , respectively. Once cooled, evacuated and sealed, the flat panel display is removed from the furnace chamber 140 . [0065] Several advantages are obtained by the preferred process. For example, circulating fluid to cool by convection more efficiently cools an assembly than by conventional conductive cooling. Fluid pathways formed within the flat panel display allow for an effective circulation of a cooling fluid during a high vacuum sealing process. Additionally, the illustrated arrangements facilitate application of a pressure differential between the inside and outside of a flat panel display, subjecting and conditioning the flat panel display to pressure differentials similar to those of the final sealed product. The same ports used to evacuate the inside of the flat panel display can be used to circulate a fluid to more quickly cool the flat panel displays. [0066] Although this invention has been described in terms of a certain preferred embodiment and suggested possible modifications thereto, other embodiments and modifications may suggest themselves and be apparent to those of ordinary skill in the art are also within the spirit and scope of this invention. Accordingly, the scope of this invention is intended to be defined by the claims that follow.
An evacuated cavity is hermetically sealed between a baseplate and faceplate of a flat panel display. Melting a glass powder, or frit, on the perimeter of the viewing area forms the hermetic seal. After melting the frit, a first fluid is circulated through the cavity to speed cooling. To further expedite the cooling of the flat panel display, a second fluid flows externally along the contour of the flat panel display to insure that the cooling is uniform and thereby avoid thermal shock.
7
CROSS-REFERENCE TO RELATED APPLICATIONS Reference is hereby made to U.S. Provisional Application for Patent Ser. No. 60/173,393, filed Dec. 28, 1999 in the name of Adel A. Ahmed, the present inventor, for APPARATUS AND METHOD FOR DERIVING ELECTRIC POWER EFFICIENTLY FROM A KEYBOARD and whereof the disclosure is hereby incorporated by reference herein. FIELD OF THE INVENTION The present invention relates to the provision of electric power to portable electrical apparatus and, more specifically, to improved apparatus for deriving electrical power from a keyboard. DESCRIPTION OF RELATED ART U.S. Pat. No. 5,911,529, entitled TYPING POWER and issued Jun. 15, 1999 in the name of Crisan, discloses a keyboard power generator having a plurality of keys with one or more magnets mounted on them. A plurality of coils are mounted on both ends of the magnets such that, when a user is typing, the magnet traverses the coils. The movement of the magnet over the coils causes an electric current to be generated. Various detailed arrangements are described for harnessing the power of movement of the keys on the keyboard for providing electrical power. The energy provided by the keyboard described by in U.S. Pat. No. 5,911,529 is stated to be usable to lengthen the operating period of a portable computer, or in the alternative, it can be used to reduce the size of the primary battery so as to result in a lighter portable computer. The disclosure of the afore-mentioned patent is herein incorporated by reference to the extent not incompatible with the present invention. SUMMARY OF THE INVENTION In accordance with another aspect of the invention, keyboard apparatus has keys for operation by a user. The keyboard comprises a first plurality of the keys being coupled to electrical generator apparatus for generating electricity from their operation; and a second plurality of said keys not being coupled to electrical generator apparatus. Keys exhibiting a relatively high usage rate are included in the first plurality of keys and keys exhibiting a relatively low usage rate are left in the second plurality. In accordance with an aspect of the invention, a keyboard apparatus having keys for operation by a user comprises a first plurality of the keys being coupled to electrical generator apparatus for generating electricity from their operation; and a second plurality of the keys not being coupled to electrical generator apparatus, the first plurality of keys exhibiting a greater average statistical frequency of usage per key than the second plurality. In accordance with the principles of the present invention, a considerable saving can be effected by equipping for electric power generation only a portion, appropriately selected, of the total number of keys on a keyboard because of the diminishing return on equipping little-used keys for power generation. In accordance with another aspect of the invention, the first plurality includes the two most frequently used keys based on statistics for a language for which the keyboard is to be used. In accordance with another aspect of the invention, the first plurality includes the three most frequently used keys based on statistics for a language for which the keyboard is to be used. In accordance with another aspect of the invention, the first plurality includes the four most frequently used keys based on statistics for a language for which the keyboard is to be used. In accordance with another aspect of the invention, the first plurality includes the N most frequently used keys based on statistics for a language for which the keyboard is to be used, where N is determined by design choice. In accordance with another aspect of the invention, the first plurality includes the N most frequently used keys based on statistics for a language for which the keyboard is primarily intended to be used, where N is determined by design choice. In accordance with another aspect of the invention, in a keyboard apparatus having keys for operation by a user, the keyboard comprises a key exhibiting the greatest average statistical frequency of usage of the keys, wherein that key is coupled to electrical generator apparatus for generating electricity from its operation; and the balance of the keys are not being coupled to electrical generator apparatus. In accordance with another aspect of the invention, a keyboard apparatus comprises a plurality of keys for operation by a user, the keyboard comprising electrical power generation apparatus for generating electrical power from mechanical energy associated with operation of keys coupled thereto; a first plurality of the keys, herein referred to as generator keys, being coupled to the electrical power generation apparatus and exhibiting a first total relative statistical frequency of usage; a second plurality of the keys, herein referred to as non-generator keys, not being coupled to the electrical power generation apparatus and exhibiting a second total relative statistical frequency of usage; the number of generator keys divided by the number of non-generator keys forming a first ratio; the first total relative statistical frequency of usage of the generator keys divided by the second total relative statistical frequency of usage of the non-generator keys forming a second ratio; and the first ratio being smaller than the second ratio. In accordance with another aspect of the invention, the first and second relative statistical frequencies of usage are determined by observation from text samples in a language for which the keyboard is primarily intended to be used. In accordance with another aspect of the invention, the first and second relative statistical frequencies of usage are determined by observation from text samples in the English language. In accordance with another aspect of the invention, a keyboard apparatus includes a plurality of keys for operation by a user, the keyboard comprising a first plurality of the keys which are coupled to electrical generator apparatus for generating electricity from their operation; and a second plurality of the keys not being coupled to electrical generator apparatus, the first plurality of keys exhibiting a total statistically greater frequency of usage than the second plurality. In accordance with another aspect of the invention, a keyboard apparatus includes a given total number of keys for operation by a user. The keyboard comprises electrical generator apparatus for generating electricity from operation of keys, a first plurality of the keys being coupled to the electrical generator, the balance of the total number of keys, not being coupled to electrical generator apparatus. The first plurality of keys exhibits a first total relative statistical frequency of usage; the balance of the total number of keys exhibits a second total relative statistical frequency of usage; and the first total relative statistical frequency of usage is greater than the second. In accordance with another aspect of the invention, a method for generating electrical power from a keyboard, comprises the steps of: determining a statistical frequency of usage for keys of the keyboard; forming a first group of keys having a given total statistical frequency of usage; forming a second group of keys having a total statistical frequency of usage less than the given total statistical frequency of usage; and coupling keys of only the first group to electrical generator apparatus for generating electricity from operation of such keys. In accordance with another aspect of the invention, a method for generating electrical power from a keyboard, comprises the steps of: determining a statistical frequency of usage for keys of the keyboard; forming a first group of keys having a first average statistical frequency of usage per key; forming a second group of keys having a second average statistical frequency of usage per key that is less than the first average statistical frequency of usage per key; and coupling keys of only the first group to electrical generator apparatus for generating electricity from operation of such keys. In accordance with another aspect of the invention, a keyboard apparatus having a given total number of keys for operation by a user, the keyboard comprising: electrical generator apparatus for generating electricity from operation of keys; a first plurality of the keys being coupled to the electrical generator; the balance of the total number of keys, not being coupled to electrical generator apparatus; the first plurality of keys exhibiting a first total relative statistical frequency of usage; the balance of the total number of keys exhibiting a second total relative statistical frequency of usage; the first and the second total relative statistical frequencies of usage being in a ratio to one another; and wherein the ratio is based on a design choice. In accordance with another aspect of the invention, the ratio is determined based on a balancing of the increased cost of including more keys in the first plurality of keys against the benefit of a greater amount of power generation. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be more fully understood from the following detailed description of preferred embodiments in conjunction with the drawing, in which FIGS. 1 and 2 show, by way of example, the frequency of usage observed experimentally in an arbitrarily selected passage in the English language, as is helpful to an understanding of the invention; FIG. 3 shows, by way of example, a graph with letters of the alphabet along the abscissa, arranged in decreasing statistical order of frequency of usage, as is helpful to an understanding of the invention; and FIGS. 4-7 show a keyboard with various keys marked with a black dot or bullet to indicate a key equipped coupled to electrical generating apparatus, in accordance with the principles of the invention. DETAILED DESCRIPTION OF THE INVENTION It is herein recognized that the most economical allocation of resources in equipping keys on a keyboard for the generation of electrical power is not necessarily to so equip all keys or an arbitrary portion of the keyboard keys. It is also herein recognized that, in a given language for which the keyboard may be primarily intended, such as, for example, the English language, there are statistical differences between the usage frequencies of the various letters. Indeed, this was recognized early by Morse in allocating telegraphic symbols to the letters of the alphabet, wherein the shortest signs were given to the most frequently letters, E being the shortest and letters such as Q, Y, and Z being allocated relatively longer symbols, so as to tend to reduce the total occupancy time of a telegraph link for a given message. It is also herein recognized that equipping certain little-used keys with electric power generation apparatus in the manner described by Crisan is not economical and, on the other, some non-letter keys, such as the frequently-used space-bar may be worth including along with frequently used letters for equipping with electric power generation apparatus. In accordance with the present invention, a determination is made on the basis of cost and return as to which keys should be equipped for electric power generation in the manner disclosed by Crisan, and which keys on the keyboard contribute so little that they need not be equipped for such power generation, on the basis of statistical frequency of usage information. FIGS. 1 and 2 show, by way of example, the frequency of usage observed experimentally in an arbitrarily selected passage in the English language. These figures are merely given here to indicate the general trend and need not be very precise or representative of a wide spectrum of English language statistics and are sufficient to explain the principles and advantages of the present invention. If need be, more exact figures can be obtained and substituted for the statistics used herein. FIG. 3 shows, by way of example, a graph with letters of the alphabet along the abscissa, arranged in decreasing statistical order of frequency of usage. Relative percentage keying power available is plotted on the ordinate scale, up to 100%. The curve relates the percentage power available to the number of keys equipped for electric power generation, beginning with the space bar key on the left as the first key, followed by the letter E and so forth. It is seen that approximately 70% of the total available keying power is obtained by equipping only 9 keys, up to and including the letter S. Furthermore, 80% of the possible total power is already achieved by equipping just 13 keys for power generation. The foregoing numbers are approximate and are based on the exemplary statistical or average relative frequency of use herein indicated. With other statistical information such as may be derived from other samples or from historical data, the results may differ a little from these results, though not by any very significant amount. FIG. 4 shows a typical keyboard with certain keys, namely the [space-bar], E, T, and A, marked with black dots to indicate that these keys are coupled to electrical generating apparatus for generating electrical power whereas unmarked keys are not. Based on the exemplary statistics for English language text referred to above, this arrangement of 4 generator keys will, on average, produce in the vicinity of 40% of the power that would be produced were substantially all the keys under consideration to be so equipped. Similarly, FIG. 5 shows 7 highest usage keys being coupled to electrical generating for power generation: [spacebar] E, T, A, I, R, and O, by which about 58% power is obtainable, in accordance with the present invention. FIG. 6 shows 11 highest usage keys being used for power generation: [spacebar] E, T, A, I, R, O, N, S, L, and H by which about 72% power is obtainable, in accordance with the present invention. FIG. 7 shows 13 high usage keys used for power generation: [spacebar], E, T, A, I, R, O, N, S, L, H, D, and C, by which about 82% power is obtainable, in accordance with the present invention. The economy of generating apparatus with a small number of keys selected in accordance with the invention is thus evident, as is also the diminishing return gained by going to a large number of keys. In accordance with an embodiment of the present invention, a selection of keys for generation of power is made with the guidance of the statistical usage data for the language under consideration. For example, one might settle for 80% of the possible energy generation. In accordance with the exemplary graph of FIG. 3, this means the inclusion of the following set for power generation: ([Space bar], E, T, A, I, R, O, N, S, L, H, D) Thus about 80% of the possible power is achieved with just 12 keys being coupled for power generation. The exact choice of statistical information to use in allocating generator keys is not critical to the invention: only that certain keys are statistically more efficient in utilizing their associated generator apparatus and that certain keys should be left out for greater economy is significant. However, in practice, the additional cost of including a key as a generator key as compared with a non-generator key as one factor will be weighed against the advantage of more or less electrical power generation in the keyboard apparatus. The additional cost will depend on such factors as the type of generator utilized, whether there is an advantage in grouping certain keys together because of row and/or column proximity and so forth. The advantage will typically include considerations of selling points, a lower selling price, customer satisfaction, and so forth. Accordingly, a point will be found on the curve of keys included that will provide desired conditions. However the selection of keys for power generation will generally comply with the principle of preferentially using the keys with the most usage, in accordance with the priniciples of the present invention. It is contemplated that embodiments used for equipping the keyboard keys for the generation of electrical power can include any of the power generation arrangements described by Crisan in the aforementioned patent, including electromagnetic induction generators, piezoelectric generators, and any other equivalent means for converting motion to a small electrical current. While the invention has been described by way of exemplary embodiments, it will be understood by one of skill in the art to which it pertains that various changes and modification can be made without departing from the spirit of the invention. Thus, for example, depending on the type of language, such as technical English as compared with, say, legal English, the key usage may differ and thus the frequency of usage of certain letters or numerals may be different. Also, it may be convenient to group the generator function for keys together in a certain manner which may provide an advantage for certain types of power generation. These and like changes are intended to be within the scope of the invention, which is defined by the claims following.
A keyboard apparatus has keys for operation by a user. The keyboard includes a first plurality of keys being coupled to electrical generator apparatus for generating electricity from their operation. A second plurality of the keys is not coupled to electrical generator apparatus. The first plurality of keys exhibits a greater average statistical frequency of usage per key than does the second plurality.
7
FIELD OF THE INVENTION This invention relates generally to methods of back flushing filters and more particularly to an improved back flushing filter construction which finds particular utility when used in the meat treating industry to filter liquid formulas that are injected into poultry, beef or pork by an injection machine by means of a pump that pumps the formulas into the meat through needles with small inlet and outlets. THE PRIOR ART The prior art is exemplified by prior issued patents such as U.S. Pat. No. 2,918,172 issued Dec.22, 1959, U.S. Pat. No. 3,074,560 issued Jan. 22, 1963 and U.S. Pat. No. 3,635,348 issued Jan. 18, 1972. With the constructions disclosed and claimed in those prior art patents, filter baskets capable of either continuous or intermittent rotation are cleaned with a doctor blade and may be additionally cleaned by a back-flushing shoe disposed inside of the basket and arranged to eject a narrow jet of liquid through a localized section of the filter basket to back-flush the filter openings as they move by the shoe. Other prior art in the filtering art of conceivable interest includes such patents as U.S. Pat. No. 4,631,126; 4,762,615; 4,818,402; 4,931,180; 5,128,029; and 5,171,433. For example, a cleaning nozzle may be used to apply flushing liquid to a stack of discs that loosen when rotated in an opposite direction. Other forms of back wash arms are also disclosed. SUMMARY OF THE PRESENT INVENTION The present invention contemplates the utilization of a large stainless steel cylindrical filter basket, or cylinder, which can be disposed in the tub or tank of a liquid stream system having a plurality of filtering stages. The cylinder walls are perforated to form an array of filter openings, which may be so small that they get stopped up with tiny pieces of meat and ingredients in the liquid formulas flowing in the liquid stream. Within the cylinder a disc plunger, or piston, is moved in a cylinder/piston relationship to compress and move effluent collected in the cylinder to back-flush the filter openings and creating a rolling action of the liquid all around the filter basket. The operation of the filter and its back-flushing feature is automated by placing the disk plunger or piston under the control of a motor means controlled by an automatic cycling machine, thereby to cycle the disk plunger or piston through a series of reciprocations within the cylinder alternated with a period of rest. The result is a greatly enhanced and lengthened effective life cycle for the filtering system before shut-down and clean up is necessary. DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevational view with parts broken away and with parts shown in cross section of a filter construction provided in accordance with the present invention and showing schematically how the filter construction is incorporated into a filtering system in order to practice the inventive methods contemplated by this invention. FIG. 2 is a view somewhat similar to that of FIG. 1, but showing the filter construction standing alone before installation into a tub, or tank of a filtering system. FIG. 3 is a top plan view of the filter construction of FIG. 2 . FIG. 4 is a side elevational view of the filter base of the filter construction shown in FIG. 2 . FIG. 5 is a plan elevational view of the filter base of FIG. 4 . DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1 of the drawings, there is shown an exemplary form of a filter construction capable of practicing the methods of the present invention and connected schematically into a filtering system typical of systems used in the meat treating industry. It should be understood that the configuration of the exemplary filter illustrated for purposes of this disclosure could be changed to utilize other geometric shapes and forms without departing from the inventive features and advantages afforded by utilization of the novel concepts set forth. Thus, in FIG. 1 there is disclosed a filter basket 10 which provides a cylinder 20 in which moves a disc plunger 30 actuated by a pair of piston rods 40 interconnected by a piston cross bar 50 so that the disc plunger, or filter piston 30 may be operated by a motor means such as an air cylinder 60 . Such a filter basket 10 is utilized with particular utility in a filtering system wherein the filter basket 10 is placed in a tank or tub 70 confining and containing part of a liquid stream in which flows liquid to be filtered, for example, liquid formula of the kind used in treating meat products, and which liquid stream has an input and an output. When incorporated in such a filtering system, the air cylinder 60 is operatively connected by conduits 61 and 62 to a source of pressurized air 63 . The filter basket 10 has an outlet 11 connected by a conduit 12 to a pump shown diagrammatically at 13 and which pump 13 pumps effluent from the filter basket 10 and directs it towards the output as shown by the arrow legend. An automatic cycling machine 80 having pre-settable control means is connected as at 81 to the source of pressurized air 63 and to the pump 13 as at 82 so that the operation of the disc plunger 30 may be selectively cycled in a selected operational pattern consisting of selectively different modes of performance, for example, the disc plunger 30 may be reciprocated within the cylinder 20 through a cycle of 4 or 5 operations and may then remain dormant, or at rest, for a pre-selected idle period of say 10-15 seconds. When so operated, the disc plunger 30 compresses and moves the effluent collected within the cylinder 20 to back-flush the liquid openings and to create a rolling action of the liquid surrounding the filter basket 10 in the tub or tank 70 . Turning now to FIGS. 2-5 of the drawings, the detailed construction of the filter 10 may be better understood. First of all, there is provided a cylinder 20 which is in effect a circumferentially continuous filter screen 21 having 4 axially spaced strengthening ribs 22 embossed to extend outwardly. The walls of the filter screen 21 are perforate, i.e., the walls are provided with an array of openings 23 through which effluent passes from outside the filter basket 10 into a chamber provided by the interior of the cylinder 20 . Referring to FIGS. 4 and 5, a filter base 24 receives the filter screen 21 at its lower edge on a raised circumferential seat 25 . In this form of the invention, the base 24 is circular and has a centrally disposed outlet opening 26 . A rim 27 extends radially outwardly from the seat 25 and terminates in an upwardly extending flange 28 . The rim 27 is apertured at four equally spaced apart locations 27 a to accommodate four tie rods each designated by a common number at 29 . In one exemplification of the invention, the filter screen 30 constitutes a 26 gauge stainless steel perforated member having filter openings 23 of 0.003 inches diameter on 0.055 center distance straight diameters, thereby providing approximately a 34% open area available for the filtering function. The top edge of the filter screen 20 is engaged by a filter cap 31 having a rim 32 with four spaced openings 32 a which likewise accommodate the tie rods 29 . Thus, with the use of fastening means such as the nuts 33 , the tie rods 29 clamp the filter screen 20 between the filter base 24 and the filter cap 31 . Disposed within the interior of the filter screen 20 is the disc plunger 30 sized and shaped to establish a piston/cylinder relationship with the filter screen 30 . The disc plunger 30 is movable on a vertical centerline axis established by the circularly configured filter disc 20 . As previously noted, the circular configuration of the filter screen could assume a different geometric shape and the shape of the disc plunger could be correspondingly matched so that sizes and shapes other than the circular shape herein disclosed could be used without departing from the spirit of this invention. As shown in FIG. 2, the disc plunger or filter piston 30 is connected to a pair of piston rods 40 , 40 and secured thereto by fastening means such as the nuts 34 . The piston rods 40 , 40 extend upwardly through the filter cap 31 and the free ends are interconnected with each other by means of a piston cross rod 50 and fastening means such as the nuts 35 . The motor means selected for providing power assistance in operating the filter piston 30 in the present exemplary disclosure is an air cylinder 60 mounted on the filter cap 31 and includes a cylinder in which moves a piston (not shown) connected to a piston rod 61 coupled to the piston cross bar 50 by means of a coupling joint 62 . By supplying compressed air from the usual type of compressed air source 63 , the air cylinder 60 will actuate the disc plunger 30 between the full line position and the dotted line position as shown in FIG. 1 . As the disc plunger filter piston 30 is moved up and down, the liquid in the cylinder is compressed and moved to back-flush the filter openings 23 removing any materials and particles plugging the filter openings 23 and creating a rolling action of the liquid surrounding the filter basket 10 . In one exemplification of the invention, the air cylinder 60 was a two position, four way spring returned pilot operated pneumatic valve electronically controlled in a selective working pattern by an automatic cycling machine 80 taking the form of a GT 3 D multi-function timer in line with a pattern selector timer logic controller. In use the filter construction is particularly effective when placed in a liquid stream flowing in a tub or tank. By pre-setting the automatic control machine 80 to regulate the air cylinder 60 via the air pressure supply 63 , and in coordination with control of the pump 13 , the disc plunger 30 will be reciprocated up and down in the cylinder 30 , thereby to compress and move the effluent collected in the cylinder to back-flush the filter openings 23 and create a swirling, rolling action in the liquid outside of the filter basket 10 . Dislodging the materials and the particles plugging the filter openings will permit the filter basket 10 to operate efficiently for a much longer time without necessitating full shut-down of the filter stream for extensive system cleaning. While a vertical stainless steel cylinder has been illustrated, the principles of the present invention could also be practiced if the filter and its plunger were disposed on a horizontal axis, or if the filter basket and its plunger were square or rectangular. Although minor modifications might be suggested by those artisans skilled in the art, it should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
A back-flushing method is practiced with a back-flushing filter construction wherein a perforate filter screen providing filter openings also forms an internal chamber for receiving the effluent from a liquid stream. A filter piston is disposed in the internal chamber and operates to divide the chamber into first and second zones on opposite sides of the piston. By selectively reciprocating the piston, the effluent in the chamber is compressed and moved on both sides of the piston. Thus, the effluent back-flushes the filter openings and creates a rolling action in the liquid surrounding the filter screen on the upstream side to dislodge particulate debris accumulated on the filter screen.
1
BACKGROUND [0001] The present invention relates to a textile machine with a sliver channel arranged in a rotating plate for a cycloid-shaped deposit of a fiber sliver in a can. [0002] Textile machines, in particular cards and draw frames are known, in which a fiber sliver is guided through a rotating plate with a sliver channel after being produced or treated. The rotating plate rotates above a can into which the fiber sliver is deposited in a cycloid-shaped manner. [0003] The sliver channel is normally a straight or curved pipe to guide the fiber sliver generally from a calendar roller to the spinning can in such manner that the fiber sliver may not suffer any wrong draft if at all possible. A wrong draft can occur if the fiber sliver is stretched, e.g. by friction, against the wall of the sliver channel during simultaneous drafting. This is especially a disadvantage when the fiber sliver has been evened out previously in a high-precision regulating draw frame. The regulation carried out before is thus again undone. Especially at high delivery speeds and high rotational speeds of the rotating plate, the forces acting upon the fiber sliver are detrimental in this respect. SUMMARY [0004] It is a principal object of the present invention to provide a rotating plate sliver channel that avoids the above-mentioned disadvantages and in particular avoids wrong drafts at high delivery speeds to a great extent. Additional objects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention. [0005] By configuring the sliver channel cross-section in accordance with the invention so that the sliver channel is subdivided into a guiding cross-section and a remaining cross-section, the fiber sliver is caused to assume a predetermined ideal line through the guiding cross-section which is provided in particular throughout the entire sliver channel from the input to the output. It is assumed in this case that, taking into account the forces acting upon the fiber sliver, the ideal line represents the shortest path for the fiber sliver through the sliver channel. By subdividing the sliver channel into a guiding cross section and a remaining cross-section, the overall cross-section of the sliver channel is made sufficiently large for the introduction of the fiber sliver into the sliver channel. On the other hand, the guiding cross-section of the sliver channel acting upon the fiber sliver as it goes through the sliver channel is sized so that a more precise guidance of the fiber sliver is achieved than in a conventional sliver channel. [0006] In the present invention, it was recognized that the sliver channel must perform different tasks. On the one hand it must be sufficiently large at the introduction of the fiber sliver into the sliver channel, i.e. when the deposit of a new fiber sliver into a can begins, so that the fiber sliver can be threaded either manually or by auxiliary mechanical or pneumatic means through the sliver channel. On the other hand the large cross-section required here is troublesome for the depositing of the fiber sliver, i.e. for the actual operation of the textile machine. Here, a sliver channel that is too large would enable the fiber sliver to move in an uncontrolled manner, rendering the deposit of the fiber sliver uneven and in addition easily causes wrong drafts. [0007] It is therefore proposed according to the invention that a guiding cross-section and a remaining cross-section of the sliver channel be provided. Here, the guiding cross-section is sized so that it compresses the fiber sliver, or at least imposes a very precise guidance upon the fiber sliver. The additional remaining cross-section facilitates the introduction of the fiber sliver into the sliver channel. If the fiber sliver is compressed in the guiding cross-section, the fiber adhesion, i.e. the friction of the individual fibers against each other and thereby the cohesion of the fiber sliver is increased. Thereby the danger of a wrong draft is reduced, since a greater traction (of equal significance as a greater tensile force) can be applied to the fiber sliver without shifting of the individual fibers relative to each other whereby the number of fibers per cross-section in the fiber sliver would be reduced. [0008] In order to compress the fiber sliver, the guiding cross-section is advantageously designed so that the walls of the sliver channel in the vicinity of the guiding cross-section converge at least in part at a sharp angle. Thereby and due to the rotational movement and the centrifugal force acting upon the fiber sliver, the latter is pressed into the guiding cross-section and adhesion is increased. Alternatively a different, suitable design of the guiding cross-section at the circumference of the sliver channel can cause the centrifugal force to press the fiber sliver more or less forcefully into the guiding cross-section. This can even go so far that the centrifugal force acting on the fiber sliver takes effect outside the guiding cross-section so that the fiber sliver is held in the guiding cross-section merely by the tensile force of the fiber sliver. [0009] In an advantageous embodiment of the invention, the remaining and/or the guiding cross section change form in the course of the sliver channel so that the fiber sliver can be influenced to meet different requirements. [0010] It has been shown to be especially advantageous if the guiding cross-section guides the fiber sliver essentially interlockingly. As a result, the guidance of the fiber sliver is especially gentle and at the same time the introduction of the fiber sliver into the sliver channel and into the guiding cross-section is facilitated. [0011] In an especially simple embodiment, the guiding cross-section is cup-shaped. In this embodiment, the fiber sliver extends within the cup. In that case, it could even be possible to dispense with the walls of the remaining cross-section. The remaining cross-section is then open in this embodiment, or at least extensively open. The sliver channel here merely consists of a straight or coiled cup in which the fiber sliver is guided. [0012] It is normally advantageous if the remaining cross-section is larger than the guiding cross-section. The remaining cross-section which is provided in particular for the introduction of the fiber sliver and for the removal of the air transported together with it, can exert the least possible negative influence on the fiber sliver with this large design. The fiber sliver will then barely come into contact with the walls of the remaining cross-section. The guiding cross-section on the other hand, exerts a sufficiently great force on the fiber sliver so that it can be guided along its ideal line through the sliver channel and if necessary can also be compressed, so that a greater traction can be exerted on the fiber sliver. [0013] An especially advantageous and even independent invention provides for the remaining cross-section and/or the guiding cross-section be subjected to suction. Thereby, fine dust or individual fibers present in the sliver channel can be sucked away. The so-called “mice” that may form in the sliver channel during the operation of the rotating plate and may fall into the spinning cans in the form of dirt can be prevented in this manner, since the particles from which the mice are formed have already been removed individually from the sliver channel. The suction to which the sliver channel is subjected, especially if it has a remaining cross-section and/or a guiding cross-section, can be effected in this case from one end or from both ends of the sliver channel, or else, in a special embodiment, through wall openings made in the remaining cross-section and/or in the guiding cross-section of the sliver channel. The removal of dust and other particles from the sliver channel without influencing the fiber sliver negatively can be effected very reliable in particular through wall openings in the remaining cross-section. If the suction takes place in the area of the guiding cross-section, this further increases the compression of the fiber sliver within the guiding cross-section and as a result an even greater traction force can be applied to the fiber sliver. [0014] If the sliver channel is formed so that the remaining cross-section and the guiding cross-section represent separate components connected to each other, the product ion of the sliver channel as well as a possibly machining of the surface inside the sliver channel can be effected very easily. Contrary to the conventional sliver channels, a composition from several components presents no problem with the sliver channel according to the invention because the fiber sliver is essentially guided in the guiding segment only and not in the remaining cross-section of the sliver channel. The interface between the guiding cross-section and the remaining cross-section of the sliver channel can thus be laid out in an area in which a fiber sliver does not normally run so that the danger that fibers may be wedged in, leading to interference with the uniformity of the fiber sliver, are avoided. [0015] The remaining cross-section and the guiding cross-section of the sliver channel are advantageously separated from each other at least partly by a wall. Thereby the guidance of the fiber sliver can be assisted by the wall in areas where it should take place within the guiding cross-section but where this is difficult to realize. On the other hand, the remaining cross-section can be made large enough in that case so that possible airflow or dirt removal continues to be possible. [0016] It is especially advantageous if a corresponding wall is located at the end of the sliver channel towards the can. Here in particular, the wall can be used to remove the accumulated and collected dirt from the sliver channel without letting it fall into the can. In that case, the opening of the remaining cross-section that transports the dirt can be designed in such a manner that it lets out into a dirt suction system through which the accumulated dirt is removed. In a simpler embodiment, a dirt catching receptacle can be provided at the remaining cross-section in which the dirt that is taken through the remaining cross-section can be collected and emptied as needed. [0017] In order to achieve especially good guidance of the fiber sliver at the sliver channel output, the end of the sliver channel towards the can may be made smaller than the rest of the sliver channel. Thereby a very precise guidance of the sliver is obtained at the sliver channel output, and thereby the deposit of the fiber sliver in the sliver channel is increased. [0018] In sliver channels of the state of the art, it was customary in the past to keep the output cross-section relatively large in order to compensate for tension peaks acting upon the fiber sliver. The pressing of the fiber sliver into the guiding cross-section now makes a greater traction force on the fiber sliver possible without damaging the fiber sliver, so that the output cross-section of the sliver channel can be made narrower and the deposit of the fiber sliver in the can would be improved. [0019] For the pneumatic introduction of the fiber sliver into the sliver channel, it is possible to design the openings of the sliver channel, in particular the opening of the remaining cross-section, so that they can be closed in order for the stream to emerge only through the guiding cross section at the end of the sliver channel and thus carry the fiber sliver with it. Following the pneumatic introduction of the fiber sliver, the opening of the sliver channel can be opened again. The openings of the sliver channel can also be closed entirely or partially during operation in order to adjust the stream management within the sliver channel. [0020] Another embodiment of the invention provides for the inside surface of the sliver channel to be at least partially coated. This coating may be such as to make friction-less sliding of the fiber sliver against the surface of the sliver channel possible. To avoid the accumulation of dirt on the inside walls of the sliver channel, it is advantageous to provide an anti-adhesion coating at least partially on the fiber sliver channel. It can be especially advantageous if the coating is especially friction-free in the area of the guiding cross-section, while an anti-adhesion coating is applied in the area of the remaining cross-section. This differentiated coating can be achieved without difficulty, e.g. through a design of the sliver channel in several parts. Other realizations of a uniform coating or different coatings in different sliver channel sections are possible. It is equally advantageous if the sliver channel is made of a low-friction material. [0021] In general, all measures that reduce the tensile traction and/or the frictional forces acting upon the fiber sliver are preferred. [0022] In a process according to the invention of the guidance of a fiber sliver in the sliver channel, the traction on the fiber sliver is such that the fiber sliver runs in a guiding cross-section of the sliver channel provided for this. The fiber sliver is then guided in a suitably designed guiding cross-section of the sliver channel in which the fiber sliver is conveyed by the traction in direction of the guiding cross-section. The traction can be greater than for conventional fiber slivers because of the design of the guiding cross-section, since the compression of the fiber sliver within the guiding cross-section permits an increase of traction force. It is even possible to process thin slivers that could no longer be drafted by conventional machines by means of the invention. [0023] If an air stream, in particular suction, is produced according to the invention along the inner surface of the sliver channel, at least in the area of the remaining cross-section of the sliver channel, this air stream can be used for the removal of dirt present inside the sliver channel. The air stream can be produced actively, by means of a suction or blowing device, as well as passively, through the configuration of the sliver channel and through its rotation. [0024] Additional advantages of the invention are shown in the embodiments below. BRIEF DESCRIPTION OF THE FIGURES [0025] FIG. 1 shows a top view of a rotating plate, [0026] FIG. 2 shows a section AA through FIG. 1 , [0027] FIGS. 3 a to c show a view of three sides of a sliver channel and [0028] FIG. 4 shows another embodiment of a sliver channel. DETAILED DESCRIPTION [0029] Reference will now be made in detail to embodiments of the invention, one or more examples of which are shown in the drawings. The embodiments are provided by way of explanation of the invention, and not as a limitation of the invention. It is intended that the invention include modifications and variations to the embodiments described herein. [0030] FIG. 1 shows a rotating plate 1 in which a sliver channel 2 is provided. The sliver channel 2 starts near the central axis of the rotating plate 1 and ends on the bottom of the rotating plate 1 with an approximately kidney-shaped opening cross-section. The sliver channel 2 is attached in the usual manner in the rotating plate 1 , e.g. by means of a poured mass 3 . [0031] The sliver channel 2 has a round cross-section. The cross-section consists of a guiding cross-section 4 and a remaining cross-section 5 . The guiding cross-section 4 in this embodiment is a partial circle connected to another partial circle of the remaining cross-section 5 . The partial circle of the guiding cross-section 4 has a clearly shorter radius than the partial circle of the remaining cross-section 5 . As a result, the fiber sliver entering the guiding cross-section 4 is more compressed and can sustain a greater traction force without damage to the fiber sliver, as described earlier. [0032] The placement of the guiding cross-section 4 relative to the position of the remaining cross-section 5 can also be different from that indicated in this embodiment. The arrangement of the guiding cross-section 4 as drawn here shows the position that the fiber sliver would essentially assume automatically when the rotating plate 1 rotates and the fiber sliver is deposited in a can. Thanks to the compression of the fiber sliver in the guiding cross-section with relatively short radius, the strength of the fiber sliver is increased, so that the depositing speed can be increased without damaging the fiber sliver. It is also possible to produce a rotation in the fiber sliver to further increase the strength of the fiber sliver. [0033] FIG. 2 shows the section AA from FIG. 1 . The sliver channel 2 is here partially cut. At the upper end of the sliver channel 2 a fiber sliver which is not shown enters the sliver channel 2 and runs through the sliver channel 2 . At the lower end of the drawing, the fiber sliver emerges and is deposited in a can which is not shown and which is standing under the rotating plate 1 . From the section through the sliver channel 2 , it can be seen that the guiding cross-section 4 represents a raised area in the cross-section of the sliver channel 2 . The fiber sliver follows this rise and is further compressed by the cross-section that is smaller than the rest of the sliver channel 2 since it is unable to spread out because of the form of the sliver channel 2 at that point. [0034] FIG. 3 shows three sides of a sliver channel 2 (“a” through “c”). The sliver channel 2 in the drawing of FIG. 3 a is shown in a side view. The guiding cross-section 4 extends in a raised groove along the sliver channel 2 from its one end to the other end. The remaining cross-section 5 constitutes the essential volume of the sliver channel 2 . While the air, as well as part of the fiber sliver, is transported in the remaining cross-section 5 , the fiber sliver is applied in the guiding cross-section 4 . Due to the shorter radius of the guiding cross-section 4 , a greater force is exerted upon the fiber sliver and thereby the fiber sliver is compressed more than in a cross-section with the radius of the remaining cross-section 5 . [0035] In order to clearly show the cross-section, FIG. 3 b shows another side view and the drawing of FIG. 3 c shows a top view of the sliver channel 2 . Especially in the top view of the sliver channel 2 , it can be seen that the radius r 1 of the remaining cross-section 5 is clearly larger than the radius r 2 of the guiding cross-section 4 . [0036] The walls of the guiding cross-section 4 and of the remaining cross-section 5 can be made from two different parts that are connected to each other. The connection can be achieved e.g. by soldering. A screw connection is however also possible. The separating line can be located in the shown curve between guiding cross-section 4 and remaining cross-section 5 . It is however also possible for the separation of the sliver channel 2 to take place e.g. exclusively in the area of the remaining cross-section 5 , for example instead of the interface points between the broken center line 6 and the wall of the remaining cross-section 5 . In this area, the contact between the wall and the fiber sliver barely applies, so that damage to the fiber sliver caused by a possible separating line can be avoided. [0037] FIG. 4 shows a lateral view of another embodiment of a sliver channel 2 . This sliver channel 2 has a guiding cross-section 4 and a remaining cross-section 5 . The output end of the remaining cross-section 5 is partially covered here by a cover 7 . In the area of the cover 7 , a separating wall 8 extending into the sliver channel 2 is provided. In addition, an opening 9 is provided at the lower end of the sliver channel 2 , through which dirt or dust particles can be aspired. The suction is effected either by a suction device that is not shown and which is installed at the opening 9 , or through injector effect which automatically produces a suction effect in the remaining cross-section 5 due to the rotation of the sliver channel 2 and which can exit e.g. through the opening 9 . [0038] The separating wall 8 and the cover 7 reduce the output cross-section of the sliver channel 2 for the fiber sliver so as to be smaller than in an embodiment without cover 7 . As a result, a precise deposit of the fiber sliver in the can is possible. The cover 7 can cover the rear portion of the remaining cross-section 5 or can be extended laterally into the area of the guiding cross-section 4 . The separating wall 8 can be provided on its end away from the output end of the sliver channel 2 with a chamfering pointing away from the guiding cross-section in order to facilitate the introduction of the fiber sliver and to prevent the fiber sliver from being guided into the area of the cover 7 . [0039] The openings 10 which are located in the area of the remaining cross-section 5 also serve for the removal of dust and dirt particles. This removal of dust and dirt particles can be effected with special efficiency if the area in which the rotating plate is located is subjected to negative pressure and a suction effect acts upon the interior of the sliver channel 2 . The removal of dirt particles thorough the openings 9 or 10 make it possible to effectively avoid so-called mice. In a special, not shown embodiment, the openings 9 and 10 can be designed so that their size can be adjusted. This makes it possible to adapt the sliver channel 2 to certain kinds of dirt on the fiber sliver or to certain qualities of the fiber sliver. The opening 9 can be connected to a negative pressure system as well as to a dirt collection container which is not shown and in which the dirt particles are collected. From there, they must be emptied as needed. [0040] The invention is not limited to the examples discussed. Thus the configuration of the cross-section of the sliver channel 2 in particular can be different, i.e. the form of the guiding cross-section as well as the form of the remaining cross section can be different. The essential point is that the fiber sliver be given guidance in the guiding cross-section so that the sliver deposit may thus take place in a clean and rapid manner.
The invention relates to a textile machine comprising a sliver channel ( 2 ) arranged in a rotating plate ( 1 ) for a cycloid-shaped deposit of a fiber sliver in a can. The sliver channel ( 2 ) is characterized in that the cross-section thereof is divided into a guiding cross-section ( 4 ) and a remaining cross-section ( 5 ). The invention also relates to a method for guiding a fiber sliver within a sliver channel ( 2 ), characterized in that the tensioning of the fiber sliver is such that the fiber sliver extends in a guiding cross-section ( 4 ) in the sliver channel ( 2 ).
1
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of application Ser. No. 12/508,758, filed Jul. 24, 2009, which is a continuation of application Ser. No. 11/247,253, filed Oct. 12, 2005, now U.S. Pat. No. 7,591,421, which is a divisional of application Ser. No. 09/981,219, filed Oct. 16, 2001, now U.S. Pat. No. 7,258,276, which claims the benefit of Provisional Application No. 60/241,907 filed Oct. 20, 2000. These applications are incorporated herein by reference in their entirety. BACKGROUND OF THE INVENTION The present invention relates to methods and systems for distributing products to customers. More particularly, the invention relates to a method and system that tracks the use of products using radio frequency tags and provides information to a central computer to enable automated restocking, inventory, tracking, or reordering of the products. The Internet, EDI, and similar systems permit businesses and ordinary consumers to order goods. However, the delivery of those goods still depends on distribution systems that are based in the physical world. The science-fiction ideal of being able to instantly have goods pop out of a computer or to receive them through a “transporter” or some other device has not yet been realized, and probably will not for many, many years. Presently, consumers may have goods shipped via various overnight delivery services. One drawback of present delivery technology is that it is primarily paper-based. Orders are made on paper and delivery involves shipping invoices, receipts, and other paperwork, which is costly to handle and annoying to many people. Even with technology that is not paper-based, ordering and receiving goods requires a number of steps. For example, for a typical Internet order, a consumer must view the applicable Web site, select the item, such as by clicking on an icon, fill out an electronic order form, and wait for the product to be delivered. Regardless of whether paper-based or electronic technology is used, present delivery methods usually require that the customer or his or her agent be present at a physical location to take the delivery of the ordered product. Further, delivery is usually made to a loading dock or similar location. This requires some internal distribution system to deliver the goods from the initial delivery point to the location where it is actually needed. SUMMARY OF THE INVENTION Accordingly, there is a need to improve the distribution of goods so that consumers experience distribution of goods at a location proximate to where the consumer will use the goods without requiring paper or computer ordering. There is also a need for a distribution system that requires less user intervention and data input than existing systems. The invention provides a system and method where a user need only find the product of interest and take that product. As compared to most Internet-based systems and methods, the invention is “clickless.” In other words, the invention requires little or no manual input from users. The invention provides a system for distributing a plurality of products. Each of the products has a radio frequency (“RF”) tag. As used herein, radio frequency means electromagnetic radiation that lies between audible and infrared radiation. Each tag is encoded with a unique identifying code. In one embodiment, the system is designed to be accessed by individuals possessing a radio frequency user badge with an identifying code. Alternatively, the system could rely on magnetic swipe cards, password systems, biometric devices (such as a retinal scanner, thumbprint reader, voice identification unit, or the like), or other systems for limiting access to authorized individuals. The system includes one or more cabinets, refrigerators, similar storage units, (generically referred to as “micro-warehouses”) or even secured rooms that are stocked with the RF tagged products and accessed by individuals through one of the mechanisms described above. In one embodiment, each micro-warehouse has a door that may be equipped with a lock (such as an electric actuated lock), an antenna or antenna array mounted on or in the micro-warehouse, a client controller coupled to the lock and the antenna, and an output device such as a light or display. Using a signal from the antenna or other input device, the client controller checks the identity of the individual accessing the micro-warehouse, such as by reading the code of the user badge. The output device is then activated to indicate whether the individual attempting to access the micro-warehouse is authorized to access the unit. If the code or other identifier matches stored records of authorized users, the client controller opens the door and the user may remove desired products from the micro-warehouse. Once the user closes the door, the client controller performs a scan of the products remaining in the micro-warehouse to determine the identity of each of the products. The client controller then generates a message including the identity of each of the products or other message related to the products taken, and sends that message to a server. The server tracks product and user information automatically, that is, without relying on user input. In particular, the server tracks product inventory, customer usage, restocking, usage frequency, faults, micro-warehouse temperature, timing, and other information. The server also generates orders for products taken from the micro-warehouse by the user. The server can be programmed to automatically place those orders, with the result that the system is “clickless.” That is, the system eliminates the need for the customer to re-order consumed items. In addition to the features noted above, the system may also locate the position or presence of one or more specific products in a micro-warehouse by conducting a scan of the micro-warehouse. In this way, the system can sense a disordered state of the product in the micro-warehouse. For example, the system can detect whether all of the components in a kit product are in the relevant kit box. Further, a product scan can detect whether any product in the micro-warehouse has been recalled, expired, or is otherwise not suitable for use. Upon detecting such a product, the system refuses access to the micro-warehouse until an administrator removes the product or otherwise addresses the situation. The invention also provides a method of distributing a plurality of products from a micro-warehouse. The method may include fitting each product with a radio frequency identification tag, positioning the plurality of products in the micro-warehouse, sensing opening and closing of the micro-warehouse door, scanning the plurality of products in the micro-warehouse upon sensing closing of the door to determine the number and type of products in the micro-warehouse, generating a message based on the number and type of products in the micro-warehouse, transmitting the message to a remote processor or server, and maintaining an inventory in the server based on the message. The method and system permit up-to-date information to be provided to the server which, in turn, can be connected to ordering and manufacturing information systems to ensure prompt re-stocking of the micro-warehouses. The system can be designed with multiple levels of access. For example, multiple micro-warehouses may be located within a secure room and a user badge may be encoded to permit a user to access the room only, a limited number of warehouses in the room, or all the warehouses in the room. As is apparent from the above, it is an advantage of the present invention to provide a method and system of identifying and distributing products. Other features and advantages of the present invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 is a schematic diagram of a system embodying the invention. FIG. 2 is schematic diagram of the server and client controller of the system shown in FIG. 1 illustrating the architecture of the enterprise application of the server and the architecture of the software on the client controller. FIG. 3 is an illustration of the flow of products and information in a distribution system of the invention. FIG. 4 a is a flowchart of the software's boot up routine of the invention. FIG. 4 b is a flowchart of the software of the invention. DETAILED DESCRIPTION Before the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. FIG. 1 illustrates a system 10 embodying the invention. The system 10 includes two servers (maintenance and commerce) 11 and 12 that create and maintain user lists, perform inventory, account, ordering functions, and monitoring functions, such as microwarehouse status, monitoring temperature and other faults. Servers 11 and 12 may communicate with a client (discussed below) using standard protocols such as TCP/IP, or other protocols over a network 13 . The network 13 may be the Internet, a telephone network, a wireless network, power line carrier (“PLC”) network, or combinations thereof. Servers 11 and 12 include standard hardware and operating system software (not shown). Running on top of the hardware and operating system software is a micro-warehouse (“MW”) enterprise application 14 . The MW enterprise application 14 accesses a profile database 15 that includes a registration module 16 , an order history module 18 , an account set-up module 20 , and a stock request module 22 . Each of the modules 16 - 22 is maintained for each client coupled to the server 12 . The modules may be configured with web content designed to be accessible using protocols for the World Wide Web section of the Internet. As best seen by reference to FIG. 2 , the MW enterprise application 14 performs numerous functions. Broadly, the MW enterprise application 14 controls the arrangement of the RFID user badges (discussed below), manages communication sessions with clients connected to the server 12 , maintains an inventory of products for each client connected to the servers 11 and 12 , checks inventory of the MW and other local MWs before ordering a product, manages security of communications, provides system administration functionality, and monitors and maintains the health of clients connected to the servers. The registration module 16 provides part of the inventory functionality of the server 12 by providing access to information regarding the location of clients connected to the server 12 . In the invention, the clients take the form of MWs. The registration module also provides access to information regarding sales persons assigned to a particular MW and identification numbers for each MW. The registration module 16 may access a MW database 24 . The order history module 18 provides a history of orders for each MW and product preferences for each MW. The account set-up module provides administrative screens for payment authorization, user information, and similar information. The stock request module 22 controls inventory replenishment based on usage and on specific customer requests and similar information. The server 12 also accesses a commerce engine 30 that uses information received from the client to generate orders that are delivered to the manufacturing infrastructure (not shown) that produces products to be distributed using the system and method of the invention. The information may be used by marketing, customer relation management (“CRM”), billing, and other systems and functions. For example, the invention may be used in the distribution of life science research products such as enzymes, assays, cloning vectors, component cells, and the like. (Of course, a wide variety of non-biological products could be distributed using the invention.) The information provided by the server 12 is used in the manufacturing infrastructure to ensure proper production of products according to the demand for such products. As noted above, the server 12 may be coupled to a plurality of clients. An exemplary client in the form of a MW 35 is shown in FIGS. 1 and 2 . While only one client is shown, the number of clients connected to the server 12 is limited only by the server's internal capacity and the capacity of the network 13 . The MW 35 may take the form of a refrigerated cabinet, a freezer, or other storage container. A secured storeroom, similar location, or other defined area could also be outfitted with a client controller and other components, as described herein, and be used to store products. As shown, the MW 35 includes a door 37 , an electric actuated lock 39 and/or a proximity sensor 40 , and an output device that may take the form of audio device or light 41 . Other output devices such as a voice synthesis device, a display screen, and the like may also be used. The MW 35 is configured with an antenna array 43 . The antenna array 43 is coupled to a client controller 45 . In one embodiment, the invention may include an antenna with two vertically polarized array antennas. The antenna 43 is an RF receive and transmit device which communicates with a transponder device or tag (discussed in greater detail below). In one embodiment, the tag is a passive tag and powered by energy from the antenna. The MW 35 may include a specialized card reader 47 in the form of a magnetic card swipe device, an antenna, a fingerprint reader, or similar device. The specialized card reader 47 is coupled to the client controller 45 via a communication link 49 . The MW 35 may also include an internal and ambient temperature sensor 55 . If included, the temperature sensor 55 is preferably positioned such that it can sense the temperature of the interior of the MW 35 . The temperature sensor 55 is coupled to the client controller 45 to provide temperature information to the client controller. Additional information may be provided to the client controller through optional input devices. The location of the MW 35 may be monitored by a global positioning system (GPS) device (not shown) plus inertial frame recognition for fine measurement and for interpolation between GPS satellite acquisitions. The voltage, frequency, and other characteristics of electrical supply lines may be monitored and provided to the client controller 45 by a power line monitoring device (also not shown). Additional input devices, such as cameras, microphones, sensors, etc., could be coupled to the client controller to monitor environmental and other conditions. The client controller 45 includes software to carry out several functions. The software included on the client controller 45 may be better understood by reference to FIG. 2 . As shown, the client controller 45 includes an operating system 60 . The operating system 60 is dependent on the type of processor used in the client controller. Preferably, the client controller 45 is an X86 single chip computer controller with a compatible operating system. If desired, the client controller 45 may be a consumer grade device such as a Palm Pilot personal digital assistant or Packet PC device, and modified according to the teachings herein. Depending on the hardware used, the client controller 45 may be configured with a graphical user interface (“GUI”) to facilitate interaction between the system 10 and its users. The client controller 45 also includes an I/O interface 62 , which may take the form of an analogue-digital, digital-analogue converter, digital input/output (ADC, DAC, and DIO) interface. The interface 62 handles input from the electric actuated lock 39 , input from the temperature sensor 55 , output to the electric actuated lock 39 , and input from optional monitoring devices such as the GPS and power line monitoring devices. In addition to the interface 62 , the client controller 45 may have two other modules: an RFID user sensing subsystem 64 and a radio frequency data collector (“RFDC”) inventory interface 66 . The RFID user sensing subsystem 64 handles input and output to and from the specialized card reader 47 . The RFDC inventory interface 66 handles input and output from the antenna 43 and handles links or sessions between the MW 35 and servers 11 and 12 . The client controller 45 includes software (not shown) which may incorporate the RFDC inventory interface 66 that reads the RFID signatures from tagged products (discussed below) placed inside the MW 35 . The software may be implemented according to algorithms disclosed in International Publication No. WO99/45495 and International Publication No. WO99/45494, the disclosures of which are hereby incorporated by reference herein. The referenced publications teach identification systems that can identify a plurality of RFID tagged items using an interrogator. The interrogator sends signals from antennas and cooperates with passive, transponder RFID tags in such a way as to eliminate or reduce interference problems that are typically associated with reading RF signals from multiple devices. The system 10 could also be implemented with active tags, although presently available active tags need to be improved so as to perform in the temperatures that the system is expected to operate within and at roughly the same cost and power consumption. Before the system 10 may be implemented, one or more RFID access badges 75 must be generated. Preferably, the RFID badges 75 , as well as the other RFID tags (discussed below) are passive transponder tags such as the tags disclosed in the above-referenced international applications. Preferably, the RFID badges 75 are encoded with information from the account set-up module 20 based on digital signatures. In addition, it is preferred that the digital signatures encoded on the RFID badges 75 used by restocking services provide one-time access to a specific MW, and thereafter expire. The RFID access badges may be fixed on a carton of products 80 . Alternatively, they may be delivered separately to the facility where the MW of interest is located. The carton of products 80 includes a plurality of individual products 90 each with an identification tag 95 . Each identification tag 95 may be the same as an RFID badge 75 , except that the digital signature on tag 95 will generally not expire. In one form of the invention, each tag 95 has a 16-bit identification code and a 72-bit item identification code. The 16-bit identification tag may be programmed with information such as the manufacturer of the product. The 72-bit item identification code is used to provide descriptive information regarding the product such as serial number, product type, date, lot number, and similar information. Once all the products 90 have been fitted with unique RFID tags 95 , the products may be shipped in the carton 80 to a designated MW such as the MW 35 . As shown in FIG. 3 , the carton 80 is packed according to a fulfillment request that is based on either an initial order from a customer (not shown) or MW specific business rules followed by the server 12 . The carton 80 may be fitted with RFID access badge 75 or the RFID access badge 75 may be shipped separately to the location of the MW of interest. If fitted with an RFID access badge 75 , the carton 80 may be shipped by a delivery service contracted to deliver the package to the MW 35 . Once the carton is delivered, the recipient or user may use the RFID access badge 75 to open the door 37 of the MW 35 by passing RFID access badge 75 in front of the reader 47 . Client controller 45 reads the digital signature of the RFID access badge 75 and confirms reading of the code by actuating a user feedback device such as a voice synthesis module or the light 41 . Since, the server 12 provides a locally based user list to the client controller 45 , the client controller 45 oversees authentication of the digital code read from the RFID access badge 75 . Client controller 45 checks the authenticity of the read code by matching the code to the user list. Client controller 45 may then optionally read the temperature sensors 55 and transmit temperature information to the server 11 . Preferably, the temperature sensor is also read on a periodic basis, with the temperature information being transmitted to the server each time the temperature is read. Client controller 45 can also be programmed to transmit temperature data if the temperature falls beneath or above a predetermined range. In many instances, it will be important to ensure that the temperature of the MW is within an appropriate range to store the products 90 . If the temperature of the MW 35 is within an appropriate range, and the user is authenticated, the client controller 45 then actuates the lock 39 to open the door 37 (of course, the MW need not be equipped with the lock 39 ). If the temperature of the MW 35 is not within an appropriate range, then access to the MW may be prevented by maintaining the lock 39 in a closed state. This would allow a refrigerated unit associated with the MW to cool the interior space of the MW to a desired temperature before ambient air was allowed into the MW by opening of the door. This also provides for product integrity during power failure. Once the door 37 opens (which may be sensed by the proximity sensor 40 ), a communication session between the MW 35 and servers 12 , which may be segmented based on appropriate events to optimize user response and network usage, begins. Having full access to the MW 35 , the employee of a carrier or logistic service who delivered the carton 80 now proceeds to place the individual items 90 into the MW 35 . Once the carton of products 80 is empty, the delivery employee then closes the door 37 , and removes the carton, if necessary. The proximity sensor 40 senses the closing of the door 37 . The client controller 45 senses the status of the sensor. Preferably, the lock 39 (if used) resets automatically after being unlocked for a predetermined time, for example five (5) seconds. The user has that predetermined time to open the door. The RFDC inventory interface 66 is disabled once the door 37 opens. When the door 37 closes, the RFDC inventory interface 66 is enabled and initiates a scan of the products placed within the MW 35 . Upon completing the scan, the client controller 45 sends a change-in-inventory message 100 to the commerce server 12 . To ensure integrity of the inventory change billed to the customer, the client controller 45 employs an integrity algorithm when the RFDC inventory interface 66 scans the MW 35 . The algorithm is based on statistical information, historical information, and other factors including RF algorithms (frequency-hopping, etc.) and delay data. The MW 35 may be accessed by a customer at the MW location using a separate RFID badge 75 shipped directly to that customer. Alternatively, and as noted above, the reader 47 may be configured as a magnetic card swipe device, barcode, a fingerprint reader, or some similar device that controls access to the MW 35 . Regardless of its exact configuration, the reader 47 reads the input from the customer and acknowledges reading of that input by lighting the light 41 . The client controller 45 then sends an input signal to the server 12 . The server 12 then conducts an authenticity review of the input. If an authorized input is received, the server 12 sends an okay message to the MW 35 . The client controller 45 may have the capability to authenticate the review as well. Once authentication takes place, the client controller 45 then opens the door 37 allowing the customer access to the interior of the MW 35 . The customer then removes one or more products 90 from the interior of the MW and then closes the door 37 . Once the door is closed, client controller 45 scans the remaining products in the MW 35 and sends a message containing the missing products to the server 12 . Identifying which products have been taken, the server 12 compares the previous inventory prior to opening, to the inventory of the missing items. From the comparison, the server 12 determines the missing items in the MW 35 . The inventory information is then communicated to the commerce engine 30 , which stores the information for future use for both marketing and inventory functions. Receipts for the used products can then be emailed or printed and shipped via regular mail to the customer at the MW location. Invoicing can also occur using electronic and standard mechanisms. The inventory message can be used for other purposes as well. For example, the inventory message includes information regarding individual products. Therefore, the amount of time a particular product spends in any MW may be recorded by the server, as well as the product's temperature history. If this time is recorded, it is also possible to compare the amount of time any particular product spends in a MW to a shelf life for that product. Temperature history can also be stored and compared to other data. If the shelf life is passed, then an expiration message, such as a pick list, may be generated and sent to the MW or an e-mail address of a user of the system to inform users of products that should be removed from the MW and not used. In addition, the inventory message may be used to determine the type of products in the MW 35 . If any of the products present within the MW 35 are subject to a recall, the MW 35 may be placed in a “lock down” condition, whereby access to the MW is denied until an administrator or other authorized individual removes the recalled product or otherwise addresses the situation. FIGS. 4 a and 4 b are flow charts of the software used in the invention. Once the client controller 45 is turned on in FIG. 4 a at step 138 , it executes a standard boot up routine at step 140 . Part of the standard boot up process enables the software to automatically update itself. At step 142 , a message is sent to the maintenance server 11 to query the current version of the controller software. If the version on the server 11 is the same as the version on the client controller 45 , the client controller 45 establishes a wait state as shown in step 152 . If the version on the server 11 is newer than the version on the client controller 45 , then the newer version is downloaded over the Internet, as shown at step 144 . The newer version is loaded into the alternative pocket or partition and written to flash memory, as shown at step 146 . Then the software is booted, as shown at step 148 . A garbage collection routine clears the old version. A message packet accompanies each boot to the maintenance server, including version status and operating status. Each boot then requests a reload of the list of authorized users from the server 11 at step 150 . The list is then reloaded at step 151 . As shown in FIG. 4 b at step 152 , the client controller 45 then establishes the wait state of the system by initializing various variables or objects such as a USER, MSG 1, MSG 2, CNT1, TEMP 1, TEMP 2, and SOLENOIDS. In addition, the client controller 45 initializes variables or objects SWITCHES, POWER, and LIGHT. Once initialization is complete, the unit is ready for user access. During this wait state, the client controller 45 performs periodic checks on the status of the MW 35 . When a customer approaches the MW and presents an RFID badge, the client controller 45 reads the user RFID badge at step 154 and checks the validity of the identification code read from the badge at step 158 . If the code does not match a valid code, an invalid user message is generated at step 162 . The message may be displayed on an output device (not shown). If an optional lock is installed on the door of the MW 35 , the client controller 45 then opens the solenoids in the lock on the MW 35 , as shown at step 166 , if the code is valid. An internal timer is then started, as shown at step 170 . In one embodiment of the invention, the proximity sensor 40 is used to detect opening of the door 37 and the status of the door. Once the door opens, the proximity sensor 40 switches its status. At step 174 , the client controller 45 checks to see if the door has been opened by reading the status of the proximity sensor 40 . If the proximity sensor 40 has not changed status, the client controller 45 will continue to check for a predetermined amount of time, as shown at step 178 . If the predetermined amount of time is exceeded, the solenoids are closed (step 182 ), which locks the lock 39 , a timeout error message is generated (step 184 ), and the client controller 45 returns to the initial state, as shown at step 186 . If the door 37 is opened within the predetermined amount of time (currently set through practice at five (5) seconds), a second timer is started, as shown at step 190 . The client controller 45 then records the internal temperature of the MW 35 at step 194 and then checks to see if the door 37 has been closed at step 200 . The client controller 45 continues to check for closing of the door for a predetermined amount of time, as shown at step 204 . If the predetermined amount of time expires, a close door message is generated as shown at step 208 and steps 190 - 204 are re-executed. Once the door 37 is closed, the client controller 45 closes the solenoids, as shown at step 212 . The client controller 45 then confirms that the door 37 is closed at step 216 and performs an inventory scan at step 220 . The data from the inventory scan is then sent to the server 12 , as shown at step 224 . The client controller 45 then returns to the initial state (step 186 ). In another embodiment, the system utilizes a defined area to enclose the tagged products rather than a cabinet. The defined area uses an access point to serve as its entryway. The products within the area are fitted with identification tags and specifically positioned in the area to be recognized by the RFDC inventory interface. Product scans begin when a sensor senses a user passing through the access point. The access point is controlled by a processor, such as the client controller 45 , and is able to restrict access to the area and products, if necessary. As can be seen from the above, the invention provides a method and system for distributing products. Various features and advantages of the invention are set forth in the following claims.
A method and system for vending products from a defined area, such as a micro-warehouse with a door. The method includes fitting each product with a radio frequency identification tag, positioning the plurality of products in a micro-warehouse, sensing opening and closing of the micro-warehouse door, scanning the plurality of products in the micro-warehouse upon sensing closing of the door to determine the number and type of products in the micro-warehouse, generating a message based on the number and type of products in the micro-warehouse, transmitting the message to a remote processor or server, and maintaining an inventory in the remote processor based on the message. The system is designed to be accessed by authorized individuals possessing some type of code or identifying mechanism. The micro-warehouses may be cabinets, refrigerators, secured rooms, or similar storage units or areas.
5
This is a division of application Ser. No. 183,132, filed Apr. 19, 1988, now U.S. Pat. No. 4,902,572. BACKGROUND OF THE INVENTION I. Field of the Invention The present invention relates to a method and apparatus for controllably depositing a thin film of material on a substrate and to the thin film products. More particularly, the present invention relates to a cryocrucible for introducing ion clusters of cryogens, such as oxygen or nitrogen, to a vacuum chamber. II. Background Information Systems are known for depositing thin films of material on a substrate. One such system comprises a housing in which a high vacuum region may be formed; a crucible containing the material to be deposited; a heater for vaporizing that material in the crucible; a nozzle for ejecting the vaporized material from the crucible through the nozzle into the high vacuum region to form non-ionized atomic clusters of the material by resultant adiabatic expansion which are held together by van der Waals forces and which drift outward from the nozzle on an approximate line of sight basis; an electrode system for converting a percentage of the non-ionized clusters into ionized clusters; and an accelerator for accelerating the ionized clusters toward the target upon which the thin film is to be deposited. Such a system, as is for example disclosed in U.S. Pat. No. 4,217,855 issued to Takagi, provides for control of deposition rate primarily through control of vapor pressure within the crucible. In addition, the ion acceleration voltage is critical in obtaining the maximum deposition rate. Crucible temperature, the shape of the ejection nozzle, the deposition material employed, and the substrate material employed are also important in determining deposition rate. Prior art systems of the Takagi type recognize the possibility of reversing the polarity on the accelerator to impede the progress of the ionized clusters without affecting the progress of the non-ionized clusters in their movement toward the target. At least one system, that disclosed in U.S. Pat. No. 4,082,636 issued to Takagi, contemplates an acceleration voltage which causes the ionized clusters to actually be repelled and thereby prohibits deposition of the ionized clusters on the target, at least during a portion of the operating time of the system. One prior art system disclosed in U.S. Pat. No. 4,197,814 issued to Takegi et al. contemplates the deposition of two or more materials on a target. This system discloses the employment of two crucibles each having a separate heating mechanism for vaporizing a different material in each crucible. The nozzles on these two crucibles are disclosed as being directed toward a common target, thereby permitting both ionized and non-ionized atomic clusters from each crucible to be simultaneously deposited on that target. With such a system, the temperatures of the crucibles may be independently regulated so as to regulate the pressures of the vapors contained in those crucibles to thereby independently control the deposition rates of the two materials. Any such change in the crucible temperature takes a considerable amount of time in comparison to the total deposition time typically required and thereby renders instantaneous control of the deposition rates effectively impossible. It is also known that systems of the type referred to above are capable of depositing an oxide of a material in a crucible, through the introduction of oxygen gas into the high vacuum region adjacent the target. However, it is difficult to control the rate and degree of oxidation using this methodology. In operating these prior art systems a layer of the film of a particular composition is deposited, the deposition process is stopped, the crucible temperature or pressure within the high vacuum region is altered, and thereafter the deposition process begun again to deposit a new composition. As a consequence, rather than being smoothly varying, a material having a series of discrete, discontinuous step changes in composition is obtained. Optical filters or antireflection coatings typically include these discrete stacked layers of dielectric material, each layer having different optical properties. New applications for these filters indicate the need to develop systems having the capacity to deposit thin film layers which have substantially smoothly or continuously varying material properties as a function of film thickness, rather than a series of discrete step-wise changes. The prior art systems are incapable of providing smoothly varying material properties because the vaporization rate (and consequently the deposition rate) responds to changes in crucible temperature too slowly. The present invention provides a system which permits a thin layer to be deposited which has smoothly or continuously varying material properties as a function of thickness of that layer, such as a film that has a continuously graded index of refraction caused by the continuously changing composition of the layer. Additional advantages of the invention will be set forth in the description which follows, and in part will be obvious from that description or may be learned by practice of the invention. SUMMARY OF THE INVENTION In accordance with the purposes of the invention as embodied and broadly described herein, a film deposition system for depositing a film of material onto a target is provided which comprises: a housing within which the target or substrate is located and within which a high vacuum region (low pressure region) may be formed; at least one crucible containing material to be deposited on the target; an evaporator for vaporizing the material in the crucible; a nozzle for ejecting vaporized material from the crucible therethrough into the high vacuum region to form non-ionized atomic clusters by resultant adiabatic expansion, the clusters traveling in a first direction through the high vacuum region, non-coincident with said target; a stripper or an ionizer for ionizing a percentage of the non-ionized clusters into ionized clusters; an accelerator for accelerating the ionized clusters; and a deflector for deflecting the ionized clusters in a second direction coincident with the target to result in a flow of non-ionized clusters along the first direction which are not deposited on the target and a flow of ionized clusters along the second direction which are deposited as a film on the target. Preferably, the evaporator of one crucible is divided into two chambers, one of which includes a cooling element so that the crucible is a "cryocrucible." Such a crucible usually contains oxygen or nitrogen as the material to be deposited, the choice being dependent on whether oxide or nitride films are being formed. This cryocrucible generally includes a first chamber opening to the high vacuum region through the nozzle, a second chamber for housing the deposition material as a liquid, and a solenoid-actuated valve connecting the chambers. Vapor may be selectively loaded from the second chamber into the first chamber for emission through the nozzle. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic illustration of a film deposition system of the present invention; FIG. 2 is an illustration of an electron stripper or electron impact ionization stage used in the system illustrated in FIG. 1; FIG. 3 is a schematic illustration of an alternative embodiment of the present invention; and FIG. 4 is a schematic illustration of a cryocrucible for use in the system of FIG. 3. DESCRIPTION OF THE PREFERRED EMBODIMENT Reference will now be made in detail to the presently preferred embodiment of the invention as illustrated in the accompanying drawings. Before discussing the cryocrucible, a film deposition system that uses the cryocrucible will be described so that the preferred environment of the invention will be understood. FIG. 1 is a schematic illustration of a deposition system comprising a housing 10, a target holder 12, a target or substrate 14 upon which a film 16 is to be deposited, crucibles 18 and 20, a heating element 22, a cooling element 24, materials 26 and 28, nozzles 30 and 32, electron impact ionization stages 34 and 36 comprising cathodes 38 and 40, shield grids 42 and 44, screen grids 46 and 48, and anodes 50 and 52, accelerators 54 and 56 comprising accelerator plates 58, 60, 62 and 64, and deflectors 66 and 68 comprising deflector plates 70, 72, 74 and 76. Nozzles 30 and 32 preferably can be of the Joule-Thomson type. Housing 10 provides a vessel within which target holder 12 and target 14 are located and within which a high vacuum region 78 may be formed. As should be well understood by those skilled in the art, a high vacuum region 78 typically has a pressure less than 10 -4 Torr. In addition to target holder 12 and target 14, the remaining elements of the system of FIG. 1 are all illustrated as being enclosed within housing 10. As should be apparent to those skilled in the art, placing every element within housing 10 is nonessential. For example, at least a portion of vessels 18 and 20 and/or at least a portion of heating element 22 and cooling element 24 may, of course, be located outside of housing 10. What is important, however, is that clusters of atoms produced from nozzles 30 and 32 have access to a clear path within high vacuum region 78 from nozzles 30 and 32 to target 14. Target 14 may comprise any form of material on which film 16 is to be deposited. Target 14 may, for example, comprise a silicon wafer substrate, glass, a metal foil, or a thin film semiconductor, as will be known to those skilled in the art. Crucibles 18 and 20 of FIG. 1 provide vessels for holding respective materials 26 and 28 which are to be deposited on target 14 to form at least a portion of film 16. Sufficient differential pressure between the vaporized material within crucible 18 and the pressure of high vacuum region 78 (a differential typically of two to four orders of magnitude) is obtained to permit adiabatic expansion of vaporized material 26 from crucible 18 through nozzle 30 into high vacuum region 78 in a manner which forms non-ionized atomic clusters of material 18, preferably on the order of 500 to 1,000 atoms per cluster. As is presently understood, the resultant non-ionized atomic clusters are held together by the attraction of van der Waals forces. Although crucible 20 may be operated with a heating element in the same manner as crucible 18 and its heating element 22, in accordance with an alternative embodiment of the present invention, crucible 20 may include a cooling element 24 in a manner which will be described in more detail below. In either event material 28 within crucible 20 is likewise expanded through corresponding nozzle 32 of crucible 20 into high vacuum region 78 to form non-ionized atomic clusters by resultant adiabatic expansion. The cooling element 24 retains a volatile material, such as oxygen or nitrogen, in the liquid state and influx of heat from the environment is satisfactory to produce the necessary evaporation. The non-ionized atomic clusters of materials 26 and 28 exiting nozzles 30 and 32 travel in respective first and second directions 80 and 82 on an approximate line of sight basis, within a distribution which extends transverse to directions 80 and 82 in a manner depending upon the particular shape of nozzles 30 and 32. For example, with a nozzle having an aspect ratio of one, the distributions along directions 80 and 82 may be approximated by cosine functions 84 and 86, respectively. As the aspect ratio is increased, more directionality and a narrower distribution is achieved; the size of the effective target areas 88 and 90 is reduced. Accordingly, the term first and second direction as used herein refers to the approximate line of sight direction of the non-ionized atomic particles issuing from the nozzle of a crucible and formed as a result of adiabatic expansion and encompasses the distribution that actually results. In the prior art systems, first direction 80 and second direction 82 are directed to intersect target 14. However, in accordance with the teachings of the present invention, first direction 80 and second direction 82 are aligned to be non-coincident with target 14. Accordingly, clusters emitted from vessels 18 and 20, unless deflected, travel along directions 80 and 82, respectively, without being deposited on target 14 as a portion of film 16. A system having at least one crucible directed at the target and at least one crucible of the type described above is also possible. Electron strippers 34 and 36 operate by electron impact to ionize or convert a selected portion of the non-ionized clusters emitted from the nozzles into ionized clusters. As may be seen in more detail in FIG. 2, electron stripper 34 comprises a wire filament cathode 38, a shield grid 42, a screen grid 46 and a plate anode 50. Wire filament cathode 38 is connected at one end to ground and at the other end to a cathode voltage V c . Plate anode 50 is coupled to a plate or anode voltage V p which is positive with respect to cathode voltage V c . Screen grid 46 is interposed between wire filaments cathode 38 and plate anode 50 and is coupled to receive a screen grid voltage V sg which may be selectively variable. Screen grid 46 is positioned to permit passage of non-ionized clusters 100 emitted from nozzle 30 between screen grid 46 and anode 50. Shield grid 42 is interposed between cathode 38 and screen grid 46 and shield grid 42 is coupled to ground. In operation, cathode 38, which preferably comprises a tungsten wire filament, is heated through application of cathode voltage V c to emit an electron beam 102 in the direction of anode 50 which preferably comprises a tungsten foil or plate. Shield grid 42 operates to shape electron beam 102 as should be well known to those skilled in the art. Screen grid 46 operates to control the degree and magnitude of electrons accelerated toward plate 50 in response to the value of screen grid voltage V sg . Thus, as non-ionized clusters 100 pass through electron beam 102, a percentage of non-ionized clusters 100 are stripped of electrons by operation of beam 102 and are thereby converted to ionized clusters 104. Since ionized clusters 104 pass through the relatively field-free region between screen grid 46 and anode 50, ionized clusters 104 continue to travel in a line of sight basis along first direction 80. By varying the screen voltage V sg , the intensity of the electron beam 102 is varied and, hence, the percentage of non-ionized clusters 100 converted to ionized clusters 104 may be accurately and quickly controlled. The percentage portion of the beam ionized is substantially linearly related to the screen voltage. Control of the ionization can therefore be effected by the type of voltage waveform selected and applied to the grid. A sinusoid, triangular, sawtooth or other voltage signal can be applied to the grid, and in each case will control the percentage ionization of the beam in accordance with the particular signal applied. Furthermore the sensitivity of the linear control is much improved over the prior art. Variations in screen voltage V sg may occur on the order of each 10 -3 to 10 -6 seconds which, for practical purposes in comparison to typical deposition time of minutes or hours, is effectively instantaneous. At a typical deposition rate of 10 Å/sec, 10 -3 sec corresponds to 0.1 Å thickness, which is much less than a monolayer. Thus, much better control is achieved than with standard methods where changes occur over several seconds only giving control over about a 30 Å layer at best. An effectively continuous control of the percentage of non-ionized clusters 100 converted to ionized clusters 104 may be obtained through operation of screen grid 46. As a result a superior product can be made having physical characteristics more accurately controlled. An optical filter having a continuously variable index of refraction can be made by the method of this invention. A ring 92 is illustrated in FIG. 2 interposed between nozzle 30 and electron stripper 34. Ring 92 is shown electrically coupled to ground and operates as an electrical shield between nozzle 30 and vessel 18 on the one hand and electron stripper 34 on the other hand. Electron stripper 36 associated with crucible 20 of FIG. 1 operates and may be constructed in precisely the same manner as electron stripper 34 described above in connection with FIG. 2, to convert a percentage of non-ionized clusters 106 of material 28 to ionized clusters 108 of material 28 which, upon exit from electron stripper 36, are traveling on a substantially line of sight basis along second direction 82. In accordance with the teachings of the present invention, a mechanism is provided for deflecting ionized clusters from a first direction non-coincident with a target to another direction coincident with that target to split the cluster beam and to establish a flow of non-ionized clusters along the first direction and a flow of ionized clusters along the coincident path. As shown in FIG. 1, deflection plates 70 and 72 of deflector 66 are aligned on either side of the beam of non-ionized clusters 100 and ionized clusters 104. Plates 70 and 72 are energized with a deflection voltage V D of sufficient magnitude to deflect ionized clusters 104 from continuing travel along first direction 80 to a third direction 110 coincident with target 16 to thereby permit deposition of ionized clusters 104 on target 16. Since non-ionized clusters 100 are not affected by deflector 66, non-ionized clusters 100 continue to travel along first direction 80 and are not deposited on target 16. Deflector 68 with deflector plates 74 and 76 operate using a deflection voltage V D' in a similar manner as deflector 66 and deflector plates 70 and 72 to deflect ionized clusters 108 traveling along second direction 82 to a fourth direction 112 which is also coincident with target 16. Thus, ionized clusters 108 are deposited on film 16 while non-ionized clusters 106, whose direction of travel is not affected by deflector 68, continue along second direction 82 and are not deposited on target 16. Ionized clusters 104, upon travel along third direction 110, continue to have a distribution 84' and a target area 88' which may be substantially identical in form to the distribution 84 and target area 88 for non-ionized clusters 100. The distribution and area, however, may be altered by focusing the beam. Target area 88' is preferably selected to cover target 14 and thereby deposit film 16 over the entire surface of target 14. In the alternative, target 88' might be selected to be smaller than target 14 to deposit material 26 only on selected locations of target 14. The deflection voltage V D may also be modulated to deposit material 26 on target 14 at selected times. Similarly, ionized clusters 108 from electron stripper 36 travel along fourth direction 112 after deflection by deflector 68 with a distribution 86' and a target area 90'. Like target area 88', target area 90' may be controlled to deposit material 28 in selected locations at selected times. The temperature for deposition varies with the choice of materials and can be as high as about 1400° C. for silver. Typical temperatures are less than 1000° C. The temperature must be high enough to allow vaporized material to exist at the reduced pressure of the high vacuum region 78, which is typically less than 10 -4 Torr. Most semiconductor materials can be deposited using the system of this invention. In particular, II-VI and III-V semiconductor materials such as ZnSe, GaAs (and Al x Ga 1-x As), and CdTe can be deposited. Using the cryocrucible, which is discussed in more detail below, such compounds as SiO, silicon nitride (Si 3 N 4 ), SiO/silicon nitride, and ZnO can be deposited. Accelerators 54 and 56 provide a mechanism for accelerating ionized clusters 104 and 108, respectively along directions 110 and 112, as is shown in FIG. 1. Accelerators 54 and 56 may comprise oppositely charged plates 58, 60 and 62, 64 having a voltage potential applied across them typically in the range of 0-10 KV. Accelerators 54 and 56 preferably are located interposed between target 14 and deflectors 66-68 as illustrated in FIG. 1 to permit non-accelerated ionized clusters 104 and 108 to be deflected by deflectors 66 and 68. As shown in FIG. 3, accelerators 54 and 56 might be located between deflectors 66, 68 and electron strippers 34 and 36. With this arrangement, however, deflectors 66 and 68 must deflect accelerated ionized clusters 104 and 108. As a consequence, the deflection voltages V D and V D' for the FIG. 3 arrangement must necessarily be greater than the deflection voltages V D and V D' for the FIG. 1 arrangement, since ionized clusters having greater kinetic energy pass through the deflector faster than ionized clusters having less kinetic energy. It should also be understood that plates 58 and 62 in FIG. 1 may, in the alternative, be located behind target 14, may actually comprise a portion of target holder 12, or may actually comprise a portion of target 14 itself. With either the FIG. 1 or FIG. 3 arrangement, since only ionized clusters 104 and 108 are deposited on target 14 to form film 16, and since the percentage of non-ionized clusters 100 and 106 converted to ionized clusters 104 and 108 by electron strippers 34 and 36, respectively, is each independently controllable by respective screen control voltages V sc and V sc' , the rate of deposition of material 26 and material 28 on target 14 may be independently and essentially instantaneously controlled. In effect, with other factors being constant, the deposition rate of material 26 on target 16 will be substantially a linear function of stripping voltage V sg and the deposition rate of material 28 on target 16 will be substantially a linear function of stripping voltage V sc' . Since voltages V sc and V sc' can be nearly instantaneously altered (altered in 10 -3 to 10 -6 seconds), the rate of deposition of materials 26 and 28 may be effectively instantaneously altered, thereby permitting an application of materials 26 and 28 either alone or in combination on target 14 which varies instantaneously as a function of the thickness of film 16. Smoothly varying the stripper voltage can produce films having smoothly varying compositions as a function of film thickness. By continuously varying the voltage, a film can be prepared to have a continuously varying composition, and, for antireflection coatings made from SiO or ZnO, might have a continously graded index of refraction because of the gradient in composition. Of course, the deflector power and accelerator can be varied to control the deposition rate alone or in combination with the other elements. Control of these electrical elements provides greater sensitivity than simply controlling the crucible temperature as done conventionally in the prior art. In accordance with the present invention, either or both crucibles 18 and 20 may be operated in conjunction with a cooling element. Specifically, as illustrated in FIG. 1, crucible 20 may include a cooling element 24 which maintains the crucible at a sufficiently low temperature to result in a vapor pressure in the crucible of about 1-10 Torr. Typically a cryocrucible operates at a temperature of about 50° K. and will emit material into a chamber 120 (FIG. 4) resulting in a pressure of about 1-10 Torr in chamber 120. Material 28 may be liquid oxygen. The cooling element 24 operates to cool the oxygen until its vapor pressure in chamber 120 is proper to permit cluster formation upon exit from nozzle 32. The cryocrucible deposition system has innumerable applications, including the capacity to make dielectric stack optical filters with a continuously variable index of refraction. As best shown in FIG. 4, the cryocrucible comprises a first chamber 120, a second chamber 124, a solenoid actuated valve 126 comprising a valve stem 128 and a solenoid coil 130, an input port 132, an output vent 134, and a thermocouple 136. Material 28, preferably in the form of liquid oxygen or nitrogen, is introduced into second chamber 124 through input port 132. Cooling element 24, which preferably comprises a cold finger from a cryo-refrigerator, operates to cool material 28 to a desired temperature as measured by thermocouple 136 to lower the vapor pressure of material 28. The vaporized portion of material 28 is introduced to chamber 120 through the solenoid actuated valve 126 at a temperature and pressure which will produce clusters 106 of material 28 upon expansion through the nozzle into the housing. Vent 134 is provided to allow chamber 124 to be initially filled and is subsequently closed when the cryocrucible temperature is the correct temperature. When chamber 124 is initially filled from a liquid oxygen tank, film boiling will occur until the chamber wets and cools to about the temperature of the liquid oxygen. During the filling step, gaseous O 2 is vented out vent 134. Although the cryocrucible concept referred to above has been disclosed in the environment of applying a film 16 to target 14, this concept has other applications as well. One of the most salient of these alternate applications is simulation of an atomic oxygen environment found in low earth orbit. Such simulation requires a directed beam of neutral oxygen atoms of approximately 5-6 eV kinetic energy. The cryocrucible provided by crucible 20 and its related elements can deliver oxygen atoms ejected in non-ionized clusters 106 having about 500 to 1,000atoms per cluster at thermal energy, namely, at low velocity. Electron stripper 36 ionizes one or a small number of atoms of selected clusters 106. The accelerating voltage applied to accelerator 56 may be adjusted to accelerate the partially ionized clusters to yield the appropriate kinetic energy. Thus, a source of low energy oxygen atoms loosely bound by van der waals forces can be prepared. The clusters have less than one percent ionization. Additional advantages and modifications will readily occur to those skilled in the art. The invention in its broader aspects is, therefore, not limited to the specific detailed representative apparatus and illustrative examples shown and described. Accordingly, departure may be made from such details without departing from the spirit or scope of applicants' generic inventive concept. The claims should be interpreted broadly, and should be limited only as is necessary in view of the pertinent prior art.
A cryocrucible permits the introduction of ion clusters of a cryogen, like oxygen or nitrogen, to a vacuum chamber, and preferably comprises a liquid cryogen containment vessel connected to an expansion chamber through a solenoid-actuated valve, a cooling means for maintaining the cryogen as a liquid in the containment vessel, and a nozzle connecting the expansion chamber to the vacuum chamber. Liquid evaporates through the valve into the expansion chamber and, then, forms clusters when it expands further while passing through the nozzle into the vacuum chamber.
2
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an intermediate potential generating circuit, and more particularly relates to an intermediate potential generating circuit for producing an intermediate potential which is between a first potential and a second potential lower than the first potential, and outputting it to an output terminal. 2. Description of the Background Art A dynamic random access memory (hereinafter referred to as DRAM) is conventionally provided with an intermediate potential generating circuit for producing an intermediate potential Vcc/2 which is between a power supply potential Vcc and a ground potential GND. Intermediate potential Vcc/2 generated in the intermediate potential generating circuit is utilized as a precharge potential of a bit line and as a cell plate potential. FIG. 3 is a circuit diagram showing a structure of a conventional intermediate potential generating circuit. With reference to FIG. 3, the intermediate potential generating circuit is provided with two reference potential generating circuits 31 and 36 and a drive circuit 41. One reference potential generating circuit 31 includes a resistor element 32, N channel MOS transistors 33, 34 and a resistor element 35 that are serially connected between a line of power supply potential Vcc (hereinafter referred to as a power supply line) 20 and a line of ground potential GND (hereinafter referred to as a ground line) 21. Each of N channel MOS transistors 33 and 34 is diode-connected. Specifically, respective gates of N channel MOS transistors 33 and 34 are connected to their own drains. Resistor elements 32 and 35 have an equal resistance value and N channel MOS transistors 33 and 34 have an equal threshold voltage Vthn. Accordingly, an intermediate node N33 between N channel MOS transistors 33 and 34 is at intermediate potential Vcc/2, and an output node N32 between resistor element 32 and N channel MOS transistor 33 is at a first reference potential Vcc/2+Vthn. The other reference potential generating circuit 36 includes a resistor element 37, P channel MOS transistors 38, 39 and a resistor element 40 that are serially connected between power supply line 20 and ground line 21. Respective gates of diode-connected P channel MOS transistors 38 and 39 are connected to their own drains. Resistor elements 37 and 40 have an equal resistance value and P channel MOS transistors 38 and 39 have an equal threshold voltage Vthp. Accordingly, an intermediate node N38 between P channel MOS transistors 38 and 39 is at intermediate potential Vcc/2, and an output node N39 between P channel MOS transistor 39 and resistor element 40 is at a second reference potential Vcc/2-Vthp. Drive circuit 41 includes an N channel MOS transistor 42 and a P channel MOS transistor 43 connected in series between power supply line 20 and ground line 21. The gate of N channel MOS transistor 42 is connected to output node N32 of reference potential generating circuit 31 and the gate of P channel MOS transistor 43 is connected to output node N39 of reference potential generating circuit 36. A node N42 between MOS transistors 42 and 43 is an output node of the intermediate potential generating circuit. An operation of this intermediate potential generating circuit will next be described. The output potential Vcc/2+Vthn of reference potential generating circuit 31 is supplied to the gate of N channel MOS transistor 42 of drive circuit 41, and the output potential Vcc/2-Vthp of reference potential generating circuit 36 is supplied to the gate of P channel MOS transistor 43 of drive circuit 41. If a potential Vout of output node N42 is lower than intermediate potential Vcc/2, N channel MOS transistor 42 becomes conductive and output node N42 is charged. At this time, the potential of the gate of N channel MOS transistor 42 is Vcc/2+Vthn, so that output node N42 which is a source of N channel MOS transistor 42 is charged only to intermediate potential Vcc/2. If potential Vout of output node N42 becomes higher than intermediate potential Vcc/2, P channel MOS transistor 43 becomes conductive and output node N42 is discharged. At this time, the potential of the gate of P channel MOS transistor 43 is Vcc/2-Vthp, so that output node N42 which is a source of P channel MOS transistor 43 is discharged only to intermediate potential Vcc/2. Therefore, potential Vout of output node N42 of the intermediate potential generating circuit is maintained at intermediate potential Vcc/2. FIG. 4 is a circuit diagram showing a structure of another conventional intermediate potential generating circuit. Referring to FIG. 4, the intermediate potential generating circuit is provided with two reference potential generating circuits 51, 56 and a drive circuit 61. One reference potential generating circuit 51 includes a P channel MOS transistor 52, an N channel MOS transistor 53, a P channel MOS transistor 54, and an N channel MOS transistor 55 connected in series between power supply line 20 and ground line 21. Each of N channel MOS transistors 53 and 55 is diode-connected. Respective gates of P channel MOS transistors 52 and 54 are connected to respective sources of N channel MOS transistors 53 and 55. Since gates of P channel MOS transistors 52 and 54 are respectively connected to nodes of low potential over N channel MOS transistors 53 and 55, each of P channel MOS transistors 52 and 54 operates as a resistor element. P channel MOS transistors 52 and 54 are identical in size, and N channel MOS transistors 53 and 55 have equal threshold voltage Vthn. Accordingly, an intermediate node N53 between N channel MOS transistor 53 and P channel MOS transistor 54 attains to intermediate potential Vcc/2, and an output node N52 between P channel MOS transistor 52 and N channel MOS transistor 53 attains to first reference potential Vcc/2+Vthn. The other reference potential generating circuit 56 includes a P channel MOS transistor 57, an N channel MOS transistor 58, a P channel MOS transistor 59 and an N channel MOS transistor 60 connected in series between power supply line 20 and ground line 21. Each of P channel MOS transistors 57 and 59 is diode-connected. Respective gates of N channel MOS transistors 58 and 60 are connected to respective sources of P channel MOS transistors 57 and 59. The gates of N channel MOS transistors 58 and 60 are respectively connected to high potential nodes over P channel MOS transistors 57 and 59, so that each of N channel MOS transistors 58 and 60 operates as a resistor element. N channel MOS transistors 58 and 60 are identical in size, and P channel MOS transistors 57 and 59 have equal threshold voltage Vthp. Accordingly, an intermediate node N58 between N channel MOS transistor 58 and P channel MOS transistor 59 attains to intermediate potential Vcc/2, and an output node N59 between P channel MOS transistor 59 and N channel MOS transistor 60 attains to second reference potential Vcc/2-Vthp. Drive circuit 61 is provided with an N channel MOS transistor 62 and a P channel MOS transistor 63 connected in series between power supply line 20 and ground line 21. The gate of N channel MOS transistor 62 is connected to output node N52 of reference potential generating circuit 51, and the gate of P channel MOS transistor 63 is connected to output node N59 of reference potential generating circuit 56. A node N62 between MOS transistors 62 and 63 is an output node of the intermediate potential generating circuit. An operation of the intermediate potential generating circuit is described below. Output potential Vcc/2+Vthn of reference potential generating circuit 51 is supplied to the gate of N channel MOS transistor 62 of drive circuit 61, and output potential Vcc/2-Vthp of reference potential generating circuit 56 is supplied to the gate of P channel MOS transistor 63 of drive circuit 61. If potential Vout of output node N62 becomes lower than intermediate potential Vcc/2, N channel MOS transistor 62 becomes conductive and output node N62 is charged up to intermediate potential Vcc/2. If potential Vout of output node N62 becomes higher than intermediate potential Vcc/2, P channel MOS transistor 63 becomes conductive and output node N62 is discharged up to intermediate potential Vcc/2. Accordingly, potential Vout of output node N62 of the intermediate potential generating circuit is maintained at intermediate potential Vcc/2. FIG. 5 is a circuit diagram illustrating a structure of still another conventional intermediate potential generating circuit. With reference to FIG. 5, the intermediate potential generating circuit differs from that in FIG. 4 in that drive circuit 61 is substituted by a drive circuit 70. Drive circuit 70 includes a P channel MOS transistor 71, an N channel MOS transistor 72, a P channel MOS transistor 73, and an N channel MOS transistor 74 connected in series between power supply line 20 and ground line 21, as well as a P channel MOS transistor 75 and an N channel MOS transistor 76 connected in series between power supply line 20 and ground line 21. The gate of N channel MOS transistor 72 is connected to output node N52 of reference potential generating circuit 51, and the gate of P channel MOS transistor 73 is connected to output node N59 of reference potential generating circuit 56. A node N72 between MOS transistors 72 and 73 is an output node of the intermediate potential generating circuit. Node N72 is connected to drains of MOS transistors 75 and 76. Gates of P channel MOS transistors 71 and 75 are both connected to a drain of P channel MOS transistor 71, and P channel MOS transistors 71 and 75 thus constitute a current mirror circuit. Gates of N channel MOS transistors 74 and 76 are both connected to a drain of N channel MOS transistor 74, and N channel MOS transistors 74 and 76 thus constitute a current mirror circuit. An operation of the intermediate potential generating circuit is next described. Output potential Vcc/2+Vthn of reference potential generating circuit 51 is supplied to the gate of N channel MOS transistor 72 in drive circuit 70, and output potential Vcc/2-Vthp of reference potential generating circuit 56 is supplied to the gate of P channel MOS transistor 73 in drive circuit 70. If potential Vout of output node,N72 becomes lower than intermediate potential Vcc/2, N channel MOS transistor 72 becomes conductive and current is caused to flow from power supply line 20 to output node N72 through MOS transistors 71 and 72. At this time, since P channel MOS transistors 71 and 75 constitute the current mirror circuit, the electric current flowing from power supply line 20 through P channel MOS transistor 75 to output node N72 has a value corresponding to the value of the current flowing through P channel MOS transistor 71. Accordingly, potential Vout of output node N72 attains to intermediate potential Vcc/2 immediately. On the other hand, if potential Vout of output node N72 becomes higher than intermediate potential Vcc/2, P channel MOS transistor 73 becomes conductive and electric current flows from output node N72 to ground line 21 through MOS transistors 73 and 74. At this time, N channel MOS transistors 74 and 76 constitute the current mirror circuit, so that the value of the electric current flowing from output node N72 through N channel MOS transistor 76 to ground line 21 has a value corresponding to that of the current flowing through N channel MOS transistor 74. Accordingly, potential Vout of output node N72 reaches intermediate potential Vcc/2 immediately. Potential Vout of output node N72 in the intermediate potential generating circuit is thus maintained at intermediate potential Vcc/2. FIG. 6 is a circuit diagram showing a structure of a further conventional intermediate potential generating circuit. With reference to FIG. 6, the intermediate potential generating circuit differs from that shown in FIG. 3 in that reference potential generating circuit 36 is eliminated and drive circuit 41 is substituted by a drive circuit 81. Drive circuit 81 is provided with two N channel MOS transistors 82 and 83 connected in series between power supply line 20 and ground line 21. The gate of N channel MOS transistor 82 is connected to output node N32 of reference potential generating circuit 31, and the gate of N channel MOS transistor 83 is connected to power supply line 20. A node N82 between N channel MOS transistors 82 and 83 is an output node of the intermediate potential generating circuit. Next, an operation of the intermediate potential generating circuit is described. Output potential Vcc/2+Vthn of reference potential generating circuit 31 is supplied to the gate of N channel MOS transistor 82 in drive circuit 81. If potential Vout of output node N82 becomes lower than intermediate potential Vcc/2, N channel MOS transistor 82 becomes conductive and a charging current I82 flows from power supply line 20 to output node N82 through N channel MOS transistor 82. At this time, since the potential of the gate of N channel MOS transistor 82 is Vcc/2+Vthn, output node N82 which is a source of N channel MOS transistor 82 is charged only to intermediate potential Vcc/2. In the meantime, since a discharging current I83 constantly flows from output node N82 through N channel MOS transistor 83 to ground line 21, potential Vout of output node N82 tends to decrease. Potential Vout of output node N82 is kept at intermediate potential Vcc/2, as discharging current I83 and charging current I82 are balanced. However, the intermediate potential generating circuits shown in FIGS. 3 to 5 do not operate normally unless requirements of Vcc>2 Vthn+2RI and Vcc>2 Vthp+2RI are met (where R represents a resistance value of the resistor element in the reference potential generating circuit, and I represents a current value flowing in the reference potential generating circuit), since they are provided with reference potential generating circuits 31, 51 including diode-connected N channel MOS transistors 33, 34; 53, 55 as well as reference potential generating circuits 36, 56 including diode-connected P channel MOS transistors 38, 39; 57, 59. On the other hand, supply voltage Vcc in a DRAM has been reduced in recent years, and threshold voltage Vthn and Vthp of the MOS transistors must be reduced in order to meet the requirements described above. However, breakdown voltage characteristic is worse in the P channel MOS transistor compared to the N channel MOS transistor in the process technique now available, so that threshold voltage Vthp of the P channel MOS transistor cannot be reduced to the level corresponding to threshold voltage Vthn of the N channel MOS transistor. For this reason, the lowest value of supply voltage Vcc is determined by threshold voltage Vthp of the P channel MOS transistor in the intermediate potential generating circuits shown in FIGS. 3 to 5. As for the intermediate potential generating circuit in FIG. 6, it is provided with only reference potential generating circuit 31 including diode-connected N channel MOS transistors 33 and 34. Therefore, it is sufficient to meet the requirement Vcc>2 Vthn+2RI only. Therefore, reduction of supply voltage Vcc becomes possible, different from the intermediate potential generating circuits in FIGS. 3 to 5 in which the lowest value of supply voltage Vcc is determined by Vthp higher than Vthn. However, the balance between charging current I82 and constantly flowing discharging current I83 cannot easily be maintained. In order to strike the balance, a circuit should be designed considering various factors such as supply voltage Vcc, temperature, and device property, and the circuit design becomes difficult. SUMMARY OF THE INVENTION An object of the present invention is to provide an intermediate potential generating circuit which realizes a stable operation even at a low supply voltage and which can be easily designed. An intermediate potential generating circuit according to the present invention generates an intermediate potential between a first potential and a second potential lower than the first potential and outputs the intermediate potential to an output terminal. The intermediate potential generating circuit is provided with a reference potential generating circuit, a charging circuit, and a discharging circuit. The reference potential generating circuit includes a first resistor element, a first diode element, a second resistor element, and a second diode element connected in series between a first potential line and a second potential line. The reference potential generating circuit outputs a reference potential which is higher than the intermediate potential by a threshold voltage of the first diode element from an output node between the first resistor element and the first diode element. The charging circuit includes a first transistor having a first electrode receiving the first potential, a second electrode connected to an output terminal, and an input electrode connected to the output node of the reference potential generating circuit, and charges the output terminal to the intermediate potential. The discharging circuit includes a third resistor element and a third diode element connected in series between the first potential line and the second potential line, and causes a prescribed discharging current to flow out from the output terminal to the second potential line. In the intermediate potential generating circuit, one reference potential generating circuit produces one reference potential, the charging circuit then charges the output terminal to the intermediate potential based on the reference potential, and the discharging circuit causes a prescribed discharging current to flow from the output terminal. The output terminal can be maintained at the intermediate potential by balancing the charging current and the discharging current. Since there is only one reference potential generating circuit, supply voltage can be reduced by providing a diode element constituted by an N channel MOS transistor for the reference potential generating circuit. Layout area can be reduced compared with the conventional circuit provided with two reference potential generating circuits, since only one reference potential generating circuit is provided. The structure between the node of intermediate potential and the second potential line in the reference potential generating circuit is identical to the structure between the output node and the second potential line in the discharging circuit, so that the output node can be maintained at the intermediate potential by applying equal current to both circuits, and the circuit can be designed more easily. Preferably, the first transistor of the charging circuit is of a first conductivity type, and the first resistor element, the first diode element, the second resistor element, and the second diode element of the reference potential generating circuit are respectively constituted by a second transistor of a second conductivity type, a third transistor of the first conductivity type, a fourth transistor of the second conductivity type, and a fifth transistor of the first conductivity type. Respective input electrodes of the third and the fifth transistors are connected to their own first electrodes, and input electrodes of the second and the fourth transistors are respectively connected to second electrodes of the third and the fifth transistors. The reference potential generating circuit can thus be constituted easily. Preferably, the third resistor element and the third diode element of the discharging circuit are respectively constituted by a sixth transistor of the second conductivity type and a seventh transistor of the first conductivity type connected in series between the output terminal and the second potential line. An input electrode of the seventh transistor is connected to its first electrode, and an input electrode of the sixth transistor is connected to a second electrode of the seventh transistor. The discharging circuit can thus be constituted easily. Preferably, the charging circuit further includes an eighth transistor of the second conductivity type having an input electrode and a first electrode connected to the first electrode of the first transistor and a second electrode connected to the first potential line, as well as a ninth transistor of the second conductivity type connected between the first potential line and the output terminal and having an input electrode connected to the input electrode of the eighth transistor. The eighth and ninth transistors constitute a current mirror circuit for causing a current flow M times higher than a current flowing in the eighth transistor from the first potential line to the output terminal. In this case, even if the output potential becomes lower than the intermediate potential, the output potential can be returned to the intermediate potential immediately, since a high charging current can be provided owing to the current amplification function of the current mirror circuit. Preferably, the discharging circuit further includes a tenth transistor of the first conductivity type connected between the output terminal and the second potential line, and having an input electrode connected to the input electrode of the seventh transistor. The seventh and the tenth transistors constitute a current mirror circuit for providing a current N times higher than a current flowing in the seventh transistor from the output terminal to the second potential line. In this case, even if the output potential becomes higher than the intermediate potential, the output potential can be returned to the intermediate potential immediately by providing a higher discharging current owing to the current amplification function of the current mirror circuit. The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a circuit diagram showing a structure of an intermediate potential generating circuit according to the first embodiment of the present invention. FIG. 2 is a circuit diagram showing a structure of an intermediate potential generating circuit according to the second embodiment of the invention. FIG. 3 is a circuit diagram illustrating a structure of a conventional intermediate potential generating circuit. FIG. 4 is a circuit diagram illustrating a structure of another conventional intermediate potential generating circuit. FIG. 5 is a circuit diagram showing a structure of still another conventional intermediate potential generating circuit. FIG. 6 is a circuit diagram showing a structure of a further conventional intermediate potential generating circuit. DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment! With reference to FIG. 1, the intermediate potential generating circuit is provided with one reference potential generating circuit 1 and a drive circuit 6. Reference potential generating circuit 1 includes a P channel MOS transistor 2, an N channel MOS transistor 3, a P channel MOS transistor 4, and an N channel MOS transistor 5 connected in series between power supply line 20 and ground line 21. Each of N channel MOS transistors 3 and 5 is diode-connected. In other words, the gate of N channel MOS transistor 3 is connected to its drain, and the gate of N channel MOS transistor 5 is connected to its drain. Gates of P channel MOS transistors 2 and 4 are respectively connected to sources of N channel MOS transistors 3 and 5. Since the gates of P channel MOS transistors 2 and 4 are respectively connected to nodes of low potential over N channel MOS transistors 3 and 5, each of P channel MOS transistors 2 and 4 operates as a resistor element. P channel MOS transistors 2 and 4 are identical in size, and N channel MOS transistors 3 and 5 have an identical size and an equal threshold voltage Vthn. Accordingly, an intermediate node N3 between N channel MOS transistor 3 and P channel MOS transistor 4 attains to intermediate potential Vcc/2, and an output node N2 between P channel MOS transistor 2 and N channel MOS transistor 3 attains to reference potential Vcc/2+Vthn. Drive circuit 6 includes an N channel MOS transistor 7, a P channel MOS transistor 8 and an N channel MOS transistor 9 connected in series between power supply line 20 and ground line 21. N channel MOS transistors 7 and 9 and N channel MOS transistors 3 and 5 in reference potential generating circuit 1 are identical in size and have equal threshold voltage Vthn, and P channel MOS transistor 8 and P channel transistors 2 and 4 in reference potential generating circuit 1 are identical in size. A gate of N channel MOS transistor 7 is connected to output node N2 of reference potential generating circuit 1. N channel MOS transistor 9 is diode-connected. In other words, a gate of N channel MOS transistor 9 is connected to its drain. A gate of P channel MOS transistor 8 is connected to ground line 21. Since the gate of P channel MOS transistor 8 is connected to a node of low potential over N channel MOS transistor 9, P channel MOS transistor 8 operates as a resistor element. A node N7 between MOS transistors 7 and 8 is an output node of the intermediate potential generating circuit. An operation of the intermediate potential generating circuit is next described. Output potential Vcc/2+Vthn of reference potential generating circuit 1 is supplied to the gate of N channel MOS transistor 7 in drive circuit 6. If potential Vout of output node N7 becomes lower than intermediate potential Vcc/2, N channel MOS transistor 7 becomes conductive and a charging current I7 flows into output node N7 from power supply line 20 through N channel MOS transistor 7. At this time, since the gate of N channel MOS transistor 7 has a potential of Vcc/2+Vthn, output node N7 which is a source of N channel MOS transistor 7 is charged up to only intermediate potential Vcc/2. Accordingly, when output node N7 becomes intermediate potential Vcc/2, N channel MOS transistor 7 becomes non-conductive, and the flow of charging current I7 into output node N7 is stopped. Meanwhile, a discharging current I9 flows out from output node N7 through MOS transistors 8 and 9 to ground line 21, and potential Vout of output node N7 tends to decrease. Potential Vout of output node N7 can be maintained at intermediate potential Vcc/2 by balancing discharging current I9 and charging current I7. At this time, since N channel MOS transistors 3 and 7 are identical in size and respective gates are connected to each other, a current I3 flowing in N channel MOS transistor 3 and current I7 flowing in N channel MOS transistor 7 are equal. The structure between intermediate node N3 and ground line 21 in reference potential generating circuit 1 (MOS transistors 4, 5) and the structure between output node N7 and ground line 21 (MOS transistors 8, 9) are identical. Therefore, potential Vout of output node N7 is normally equal to potential Vcc/2 of the intermediate node of reference potential generating circuit 1. If potential Vout of output node N7 becomes higher than intermediate potential Vcc/2, each resistance value of MOS transistors 8 and 9 decreases by the difference between potential Vout and intermediate potential Vcc/2, so that discharging current I9 increases and output potential Vout immediately returns to intermediate potential Vcc/2. In the intermediate potential generating circuit according to this embodiment, only reference potential generating circuit 1 including a resistor element constituted by a P channel MOS transistor and a diode constituted by an N channel MOS transistor is provided and there is no reference potential generating circuit including a diode constituted by a P channel MOS transistor, so that threshold voltage Vthp of the P channel MOS transistor does not affect an operating condition, and only threshold Vthn of the N channel MOS transistor is related to the operating condition. More specifically, among the requirements described above, only the requirement of Vcc>2 Vthn+2RI should be met and it is not necessary to meet the requirement of Vcc>2 Vthp+2RI. Therefore, reduction of supply voltage Vcc becomes possible, different from the conventional circuit in which the lowest value of supply voltage Vcc is determined by Vthp higher than Vthn. Compared with the conventional circuit provided with two reference potential generating circuits, the circuit of this embodiment provided with only one reference potential generating circuit can have reduced layout area. Since the structure between intermediate node N3 and ground line 21 in reference potential generating circuit 1 and the structure between output node N7 and ground line 21 are identical, output node N7 can thus be maintained at intermediate potential Vcc/2 if an equal amount of current is provided in both structures, and the circuit can be designed more easily. Second Embodiment! With reference to FIG. 2, the intermediate potential generating circuit differs from that shown in FIG. 1 in that drive circuit 6 is substituted by a drive circuit 10. Drive circuit 10 includes a P channel MOS transistor 11, an N channel MOS transistor 12, a P channel MOS transistor 13, and an N channel MOS transistor 14 connected in series between power supply line 20 and ground line 21 as well as a P channel MOS transistor 15 and an N channel MOS transistor 16 connected in series between power supply line 20 and ground line 21. The gate of N channel MOS transistor 12 is connected to output node N2 of reference potential generating circuit 1, and the gate of P channel MOS transistor 13 is connected to ground line 21. Since the gate of P channel MOS transistor 13 is connected to a node of low potential over an N channel MOS transistor 14, P channel MOS transistor 13 operates as a resistor element. A node N12 between MOS transistors 12 and 13 is an output node of this intermediate potential generating circuit. Node N12 is connected to drains of MOS transistors 15 and 16. Gates of P channel MOS transistors 11 and 15 are both connected to a drain of P channel MOS transistor 11, and P channel MOS transistors 11 and 15 thus constitute a current mirror circuit. Gates of N channel MOS transistors 14 and 16 are both connected to a drain of N channel MOS transistor 14, and n channel MOS transistors 14 and 16 constitute a current mirror circuit. An operation of the intermediate potential generating circuit is next described. Output potential Vcc/2+Vthn of reference potential generating circuit 1 is supplied to the gate of N channel MOS transistor 12 of drive circuit 10. If potential Vout of output node N12 becomes lower than intermediate potential Vcc/2, N channel MOS transistor 12 becomes conductive and a charging current I11 flows into output node N12 from power supply line 20 through MOS transistors 11 and 12. At this time, since P channel MOS transistors 11 and 15 constitute the current mirror circuit, a current I15 which is M times larger than a current I11 flowing in P channel MOS transistor 11 is supplied from power supply line 20 through P channel MOS transistor 15 into output node N12 (M is a current amplification rate of the current mirror circuit constituted by P channel MOS transistors 11 and 15 and is a positive real number). Accordingly, potential Vout of output node N12 immediately becomes potential Vcc/2. In the meantime, a discharging current I14 flows from output node N12 through MOS transistors 13 and 14 to ground line 21, and a current I16 which is N times larger than discharging current I14 flows out from output node N12 through N channel MOS transistor 16 to ground line 21 (N is a current amplification rate of the current mirror circuit constituted by P channel MOS transistors 14 and 16 and is a positive real number). Therefore, potential Vout of output node N12 tends to decrease. Potential Vout of output node N12 can be maintained at intermediate potential Vcc/2 by balancing discharging currents I14 and I16 and charging currents I11 and I15. If potential Vout of output node N12 becomes higher than intermediate potential Vcc/2, each resistance value of MOS transistors 13, 14 and 16 decreases by the difference between Vout of output node N12 and intermediate potential Vcc/2, so that-discharging current I14 and I16 increase and output potential Vout immediately becomes intermediate potential Vcc/2. Accordingly, output potential Vout is maintained at intermediate potential Vcc/2. In the intermediate potential generating circuit according to this embodiment, the same effect as that of the first embodiment can be obtained, and larger charging/discharging current flows compared with the first embodiment, so that output potential Vout is corrected to Vcc/2 immediately even if output potential Vout deviates from intermediate potential Vcc/2, and output potential Vout is accordingly stabilized. If reduction of threshold voltage Vthp of P channel MOS transistor is more easily realized than reduction of threshold voltage Vthn of N channel MOS transistor owing to the improvement of the process technique, similar effect can be obtained by reversing the conductivity type of the MOS transistors and exchanging power supply line 20 and ground line 21 in FIGS. 1 and 2. Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims.
In an intermediate potential generating circuit provided in a DRAM, a reference potential generating circuit includes two combinations of a resistor element constituted by a P channel MOS transistor and a diode constituted by an N channel MOS transistor, and outputs a reference potential Vcc/2+Vthn. A charging circuit constituted by an N channel MOS transistor charges an output node to an intermediate potential Vcc/2 based on the reference potential. A discharging circuit includes one combination of a resistor element constituted by a P channel MOS transistor and a diode constituted by an N channel MOS transistor, and provides a prescribed current flowing from the output node. Reduction of supply voltage Vcc becomes possible by eliminating a diode constituted by a P channel MOS transistor which makes reduction of a threshold voltage Vthp difficult.
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CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a divisional of a prior application entitled “A SYSTEM AND PROCESS FOR REGRESSION-BASED RESIDUAL ACOUSTIC ECHO SUPPRESSION”, which was assigned Ser. No. 11/097,548 and filed Mar. 31, 2005. BACKGROUND [0002] 1. Technical Field [0003] The invention is related to residual echo suppression in a microphone signal which been previously processed by an acoustic echo canceller (AEC), and more particularly to a regression-based residual echo suppression (RES) system and process for suppressing the portion of the microphone signal corresponding to a playback of a speaker audio signal that was not suppressed by the AEC. [0004] 2. Background Art [0005] In teleconferencing applications or speech recognition, a microphone picks up sound that is being played through the speakers. In teleconferencing this leads to perceived echoes, and in speech recognition, reduction in performance. Acoustic Echo Cancellers (AECs) are used to alleviate this problem. [0006] However, the echo reduction provided by AEC is often not sufficient for applications that require a high level of speech quality, such as speech recognition. The insufficient echo reduction is caused by, among other things, adaptive filter lengths in AEC that are much shorter that the room response. Short AEC filters are used to make AEC computationally feasible and to achieve reasonably fast convergence. Various methods have been employed to suppress the residual echo. For example, techniques such as coring (also referred to as center clipping) were used. However, this can lead to near-end speech distortion. [0007] Other methods to remove the residual echo tried to achieve this goal by estimating its power spectral density (PSD), and consequently removing it using Weiner filtering [1,2] or spectral subtraction [3]. However, most of those methods either need prior information about the room, or make unreasonable assumptions about signal properties. For example, some methods estimate PSD based on long-term reverberation models of the room [3]. Parameters of the model are dependent on the room configuration and need to be calculated in advance based on the behavior of the room impulse response. [0008] There are some techniques that estimate the residual echo PSD via a so-called “coherence analysis” which is based on the cross-correlation between the speaker signal (sometimes referred to as the far-end signal in teleconferencing applications) and the residual signal. In a sub-band system, only the discrete Fourier transforms (DFTs) of the windowed signals are available, so the cross-correlations can be only approximately calculated [1]. In [2], the coherence function is computed based on a block of a few frames of data; in [1] it is based on multiple blocks. The latter assumes that the frames of the speaker signal are uncorrelated, which is almost never true. The performance of these algorithms is dictated by the accuracy of the PSD estimate and their ability to track it accurately from one frame to another. The accuracy decreases when near-end speech is present or when the echo path changes. [0009] It is noted that in the preceding paragraphs, as well as in the remainder of this specification, the description refers to various individual publications identified by a numeric designator contained within a pair of brackets. For example, such a reference may be identified by reciting, “reference [1]” or simply “[1]”. A listing of references including the publications corresponding to each designator can be found at the end of the Detailed Description section. SUMMARY [0010] The present invention is directed toward a system and process for suppressing the residual echo in a microphone signal which been previously processed by an acoustic echo canceller (AEC), which overcomes the problems of existing techniques. In general, the present system and process uses a regression-based approach to modeling the echo residual. In other words, a parametric model of the relationship between the speaker and the echo residual after AEC is built and then these parameters are learned online. Thus, instead of estimating the power spectral density (PSD), a prescribed signal attribute (e.g., magnitude, energy, or others) of the short-term spectrum of the AEC residual signal is directly estimated in terms of the same attribute of the short-term spectra of the speaker signal using the parameterized relations. This scheme is powerful since, regression models can easily capture complex empirical relationships while providing flexibility. Tracking the parameters can be easily done using stochastic filters. Prior knowledge about room reverberation is not needed. [0011] In one embodiment of the present system and process, the residual echo present in the output of an acoustic echo canceller (AEC) is suppressed using linear regression between the spectral magnitudes of multiple frames of the speaker signal and the spectral magnitude of the current frame of the echo residual as found in the output of an acoustic echo canceller AEC, per sub-band. The sub-bands are computed using a frequency domain transform such as the Fast Fourier Transform (FFT) or the Modulated Complex Lapped Transform (MCLT). In the tested embodiment, the MCLT is used to convert the time domain signals to the frequency domain. This model automatically takes into consideration the correlation between the frames of the speaker signal. The regression parameters are estimated and tracked using an adaptive technique. [0012] The present regression-based echo suppression (RES) system and process is both simple and effective. Preliminary results using linear regression on magnitudes of real audio signals demonstrate an average of 8 dB of sustained echo suppression in the AEC output signal under a wide variety of real conditions with minimal artifacts and/or near-end speech distortion. [0013] As indicated previously, in the present RES system and process, a portion of a microphone signal corresponding to a playback of a speaker audio signal sent from a remote location and played back aloud in a near-end space is suppressed. In one embodiment, this involves first processing the microphone signal using an AEC module that suppresses a first part of the speaker signal playback found in the microphone signal and generates an AEC output signal. A RES module is then employed. This module inputs the AEC output signal and the speaker signal, and suppresses at least a portion of a residual part of the speaker signal playback found in the microphone signal, which was left unsuppressed by the AEC module. The output of the RES module can be deemed the final RES output signal. However, additional suppression of the remaining portion of the speaker signal playback may be possible by employing one or more additional RES modules. In the multiple RES module embodiments, one or more additional RES modules are added, with each inputting the signal output by the preceding RES module and the speaker signal. The additional module then suppresses at least a portion of a remaining part of the speaker signal playback found in the microphone signal, which was left unsuppressed by the AEC module and all the preceding RES modules. The output of the last RES module is designated as the final RES signal. [0014] The process used by each RES module is the same, only the input signals change. More particularly, in the case of the first (and perhaps only) RES module, the following suppression process is used for each segment of the AEC output signal, one by one, in the order in which the frame is generated. A segment can correspond to a single frame of the AEC output, as in tested embodiments of the present invention. However, in alternative embodiments, a segment can comprise multiple frames or fractions of frames, perhaps depending on external parameters, such as room size. Within each frame, a pre-defined range of sub-bands found within the overall frequency range are processed. First, a previously unprocessed sub-band within a prescribed overall frequency range is selected. The desired signal attribute of this band is calculated (e.g. magnitude, energy). The echo residual component associated with the selected sub-band as exhibited in the prescribed signal attribute is then predicted using a prescribed regression technique, based on a prescribed number of past periods of the speaker signal and a current set of regression coefficients. The result of this prediction is subtracted from a measure of the same signal attribute in the segment of the AEC output signal currently under consideration, to produce a difference. In addition, the noise floor of the segment of the AEC output signal currently under consideration is computed in terms of the prescribed signal attribute. It is next determined if the aforementioned difference is lower than the computed noise floor. If not, then the difference is designated as a RES output for sub-band pertaining to the segment of the AEC output signal currently under consideration, and otherwise the noise floor is designated as the RES output. The RES output signal component for the selected sub-band and the segment of the AEC output signal currently under consideration is generated from the designated RES output. [0015] As mentioned previously, the regression coefficients can be adaptively updated as the suppression process continues. If so, it is next determined if the segment of the AEC output signal currently under consideration contains human speech components that originated in the near-end space. Whenever this is not the case, a smoothed speaker signal power is estimated for the same time period and selected sub-band. This is followed by computing a normalized gradient and updating the regression coefficients. If the regression coefficients have been updated or it was determined that the segment of the AEC output signal currently under consideration contains near-end speech components, the last computed regression coefficients are designated as the coefficients that are to be used for the associated sub-band to predict the AEC output signal echo residual component for the next segment of the AEC output signal to be considered. [0016] The process continues by determining if there are any remaining previously unselected sub-bands. If so, another one of the sub-bands is selected and the foregoing process is repeated until there are no previously unselected sub-band-ranges remaining. At that point, the RES output signal components generated for each previously selected sub-band are combined and the combined signal components are designated as the RES output for the segment of the AEC output signal currently under consideration. [0017] It is noted that the same process is used if the RES module in question is not the first, except that the output from the preceding RES module is used as an input in lieu of the AEC output signal. [0018] The present RES system and process is also applicable to stereo residual suppression as well. Current stereo AEC techniques have problems with correlations between the right and left channels, however, the present RES approach can naturally handle these correlations by removing them in two passes. Thus, at least two RES modules are employed. Essentially, there is no difference in the processing itself, only a difference in which signals are input to the RES modules. [0019] More particularly, in one embodiment of the present RES system and process applicable to stereo, a portion of a microphone signal corresponding to a playback of the right and left channels of a far-end stereo audio signal sent from a remote location, and each of which is played back aloud via separate loudspeakers in a near-end space, is suppressed. Alternatively, the stereo audio signal can be generated on the near end computer (e.g. playing music from a CD). This processing involves first processing the microphone signal using a stereo AEC module that suppresses a first part of the playback of the left and right channels of the speaker signal found in the microphone signal and generates an AEC output signal. A first RES module is then employed, which inputs the AEC output signal and one of the channels of the speaker signal. The first RES module suppresses at least a portion of a residual part of the speaker signal playback of the input channel found in the microphone signal which was left unsuppressed by the AEC module, to produce a first RES output signal. Then, a second RES module inputs the first RES output signal and the other channel of the speaker signal (i.e., the one not input by the first RES module). This second RES module suppresses at least a portion of a residual part of the speaker signal playback of the input channel found in the microphone signal which was left unsuppressed by the AEC module and the first RES module, to produce a final RES output signal. This method is also applicable to multi-channel playback where the number of playback channels is greater than 2 (e.g. 5.1, 7.1, and so on). [0020] In an alternate embodiment of the present RES system and process applicable to stereo, the foregoing modules operate in the same way, except in this case, the first RES module inputs either the sum or difference of the two channels of the speaker signal and the second RES module inputs the sum or difference of the speaker signal—whichever one was not input by the first RES module. [0021] In addition to the just described benefits, other advantages of the present invention will become apparent from the detailed description which follows hereinafter when taken in conjunction with the drawing figures which accompany it. DESCRIPTION OF THE DRAWINGS [0022] The specific features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where: [0023] FIG. 1 is a diagram depicting a general purpose computing device constituting an exemplary system for implementing the present invention. [0024] FIG. 2 is a block diagram depicting an overall echo reduction scheme including a regression-based residual echo suppression (RES) module in accordance with the present invention. [0025] FIG. 3 shows a flow chart diagramming one embodiment of a RES process according to the present invention employed by the RES module of FIG. 2 for suppressing the portion of the microphone signal corresponding to a playback of the speaker audio signal that was not suppressed by the AEC module. [0026] FIG. 4 is a block diagram depicting an overall echo reduction scheme including a regression-based residual echo suppression (RES) technique involving two sequential RES modules in accordance with the present invention. [0027] FIG. 5 is a block diagram depicting an overall echo reduction scheme for stereo playback scenarios including a regression-based residual echo suppression (RES) technique involving two sequential RES modules in accordance with the present invention, where the first RES module handles the left channel and the second RES module handles the right channel. [0028] FIG. 6 is a block diagram depicting an alternate overall echo reduction scheme for stereo playback scenarios including a regression-based residual echo suppression (RES) technique involving two sequential RES modules in accordance with the present invention, where the first RES module inputs a sum of the left and right stereo channels and the second RES module inputs a difference of the left and right stereo channels. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0029] In the following description of the preferred embodiments of the present invention, 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 understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. 1.0 The Computing Environment [0030] Before providing a description of the preferred embodiments of the present invention, a brief, general description of a suitable computing environment in which portions of the invention may be implemented will be described. FIG. 1 illustrates an example of a suitable computing system environment 100 . The computing system environment 100 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the invention. Neither should the computing environment 100 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in the exemplary operating environment 100 . [0031] The invention is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the invention include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like. [0032] The invention may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. 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. In a distributed computing environment, program modules may be located in both local and remote computer storage media including memory storage devices. [0033] With reference to FIG. 1 , an exemplary system for implementing the invention includes a general purpose computing device in the form of a computer 110 . Components of computer 110 may include, but are not limited to, a processing unit 120 , a system memory 130 , and a system bus 121 that couples various system components including the system memory to the processing unit 120 . The system bus 121 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as Mezzanine bus. [0034] Computer 110 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 110 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computer 110 . Communication media typically embodies computer readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer readable media. [0035] The system memory 130 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 131 and random access memory (RAM) 132 . A basic input/output system 133 (BIOS), containing the basic routines that help to transfer information between elements within computer 110 , such as during start-up, is typically stored in ROM 131 . RAM 132 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 120 . By way of example, and not limitation, FIG. 1 illustrates operating system 134 , application programs 135 , other program modules 136 , and program data 137 . [0036] The computer 110 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 1 illustrates a hard disk drive 141 that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 151 that reads from or writes to a removable, nonvolatile magnetic disk 152 , and an optical disk drive 155 that reads from or writes to a removable, nonvolatile optical disk 156 such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 141 is typically connected to the system bus 121 through a non-removable memory interface such as interface 140 , and magnetic disk drive 151 and optical disk drive 155 are typically connected to the system bus 121 by a removable memory interface, such as interface 150 . [0037] The drives and their associated computer storage media discussed above and illustrated in FIG. 1 , provide storage of computer readable instructions, data structures, program modules and other data for the computer 110 . In FIG. 1 , for example, hard disk drive 141 is illustrated as storing operating system 144 , application programs 145 , other program modules 146 , and program data 147 . Note that these components can either be the same as or different from operating system 134 , application programs 135 , other program modules 136 , and program data 137 . Operating system 144 , application programs 145 , other program modules 146 , and program data 147 are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 110 through input devices such as a keyboard 162 and pointing device 161 , commonly referred to as a mouse, trackball or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 120 through a user input interface 160 that is coupled to the system bus 121 , but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB). A monitor 191 or other type of display device is also connected to the system bus 121 via an interface, such as a video interface 190 . In addition to the monitor, computers may also include other peripheral output devices such as speakers 197 and printer 196 , which may be connected through an output peripheral interface 195 . A camera 192 (such as a digital/electronic still or video camera, or film/photographic scanner) capable of capturing a sequence of images 193 can also be included as an input device to the personal computer 110 . Further, while just one camera is depicted, multiple cameras could be included as input devices to the personal computer 110 . The images 193 from the one or more cameras are input into the computer 110 via an appropriate camera interface 194 . This interface 194 is connected to the system bus 121 , thereby allowing the images to be routed to and stored in the RAM 132 , or one of the other data storage devices associated with the computer 110 . However, it is noted that image data can be input into the computer 110 from any of the aforementioned computer-readable media as well, without requiring the use of the camera 192 . [0038] The computer 110 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 180 . The remote computer 180 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to the computer 110 , although only a memory storage device 181 has been illustrated in FIG. 1 . The logical connections depicted in FIG. 1 include a local area network (LAN) 171 and a wide area network (WAN) 173 , but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet. [0039] When used in a LAN networking environment, the computer 110 is connected to the LAN 171 through a network interface or adapter 170 . When used in a WAN networking environment, the computer 110 typically includes a modem 172 or other means for establishing communications over the WAN 173 , such as the Internet. The modem 172 , which may be internal or external, may be connected to the system bus 121 via the user input interface 160 , or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 110 , or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation, FIG. 1 illustrates remote application programs 185 as residing on memory device 181 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used. [0040] The exemplary operating environment having now been discussed, the remaining parts of this description section will be devoted to a description of the program modules embodying the invention. 2.0 Regression-Based Residual Echo Suppression [0041] The role of the present regression-based residual echo suppression (RES) system in an overall echo reduction scheme is illustrated in FIG. 2 . The speaker signal x(t) 202 coming from a remote location is received and played back in the space represented by near-end block 200 via loudspeaker 204 . The far end signal playback 206 , as well as the ambient noise n(t) 208 in the near-end space and near-end speech s(t) 210 is picked up by the microphone 212 which produces a microphone signal 214 . This microphone signal 214 is fed into a conventional AEC module 216 which suppresses a part of the speaker signal playback picked up by the microphone. The output of the AEC module 216 is the AEC signal m(t) 218 , which is in turn fed into the RES module 220 . The RES module 220 uses this signal and the speaker signal 202 (which is also fed into the AEC module 216 ) to produce the final RES output signal b(t) F 222 in the manner that will be described next. [0042] In RES it is desired to directly estimate the amount of residual echo energy in each frame of AEC output. This is achieved by modeling the empirical relationship between the speaker signal and the echo residual. The output of the AEC m(t) can be expressed as [0000] m ( t )= x ( t )* h l ( t )+ s ( t )+ n ( t )   (1) [0000] where s(t) is the near-end signal at the microphone, x(t) is the far-end or speaker signal, n(t) is the ambient noise, and k l (t) is the uncompensated part of the room impulse response. The echo residual after AEC, r(t), is [0000] r ( t )= x ( t )* h l ( t ),   (2) [0000] where * denotes convolution. In the frequency domain, this is expressed as: [0000] R ( f )= X ( f ) H l ( f ). (3) [0043] This expression holds true only when infinite duration signals are considered. In reality, the signals are processed on a frame-by-frame basis (typically of 20 ms duration) and the true relationship between the short-term frames is complex. In general, the current frame of the residual signal can be expressed in terms of the current and past speaker signal frames: [0000] R ( f,t )= g Θ ( X ( f,t ), X ( f,t− 1), . . . , X ( f,t−L+ 1)),   (4) [0000] where f and t represent the frequency and time index respectively, g represents an unknown function, Θ is the set of parameters of the model, and L depicts the model order. Once a good estimate of R(f,t) is obtained, it can be subtracted from the AEC signal. [0044] Typically, a room impulse response lasts a few hundred milliseconds. Depending on the number of taps, the AEC is able to model and cancel the effect of the relatively early echoes. The AEC residual can reasonably be assumed to be a part of the early echo and most of the late-echoes, also called long-term room response, or late reverberation. The late reverberation consists of densely packed echoes that can be modeled as white noise with an exponentially decaying envelope [4]. This, combined with the belief that the AEC captures a significant part of the phase information, leads to the belief that whatever phase information is left behind will be very difficult to track. Instead, the present system and process uses attributes of the signal (e.g., magnitude, energy) of the short-term spectrum of the echo residual expressed in terms of the same attribute of the current and previous frames of the speaker signal. [0045] The present invention can employ any appropriate regression model (e.g., linear regression, kernel regression, decision tree regression, threshold linear models, local linear regression, and so on including non-linear models). However, it has been found that a simple linear model is quite effective, especially if the RES is applied more than once, as will be discussed later. In addition, of the aforementioned signal attributes, it has been found that magnitude is particularly effective. Thus, the following description will describe the invention in terms of a linear regression magnitude model. However, it is not intended that the present invention be limited to just this embodiment. Rather any appropriate regression model and any signal attribute could be employed instead without exceeding the scope of the invention. [0046] Given the use of a linear regression model and magnitude as the signal attribute under consideration: [0000] |R(f,t)|≈Σ i=0 L 1 w i |X(f,t−i)|  (5) [0000] where w i are the regression coefficients for the magnitude model. Adaptive RES [0047] More particularly, the present RES system and process involves predicting the echo residual signal magnitude {circumflex over (R)}(f,t) in the AEC output signal for each frequency sub-band of interest, identified by a frequency index f, and for each time period identified by a time index t (which in tested embodiments was each frame of the AEC output signal), as: [0000] {circumflex over (R)} ( f,t )=Σ i=0 L-1 w i ( t )| X ( f,t−i )|.   (6) [0000] In tested embodiments f ranges from 2-281 (starting at band 0) with each index number representing a 25 Hz span, t ranges from 1 to the last frame of interest output by the AEC, L is the regression order, w i (t) for i=[0 . . . L-1] are the regression coefficients for time period t, and |X(f,t−i)| is the magnitude of the speaker signal for sub-band f over prior time period t−i for i=[0 . . . L-1]. The regression order L is chosen according to the room size. Since higher frequency signal components are absorbed better than lower frequency signal components [4], a relatively smaller value of L is used at higher frequencies. For example, in tested embodiments of the present RES system and process, L=10, 13 and 16 was chosen for sub-bands 2-73 (lower frequencies) and L=6, 8 and 10 for sub-bands 74-281 (higher frequencies), for small, medium, and large rooms respectively. The initial regression coefficients (i.e., w i (1)) are set to zero. These coefficients are adapted thereafter as will be described shortly. Finally, it is noted that |X(f,t)| is deemed to be 0 for t≦0. [0048] Once {circumflex over (R)}(f,t) is predicted for the current time period t and a particular sub-band, it can be used to remove some or all of the residual echo in the AEC signal. This removal can be accomplished in a number of ways, including spectral subtraction and Weiner filtering. The spectral subtraction method is the simplest and is described herein. First, {circumflex over (R)}(f,t) is subtracted from the magnitude of the current frame of the AEC signal |M(f,t)| associated with the same time period and sub-band, to produce an error signal E(f,t), as: [0000] E ( f,t )=| M ( f,t )|− {circumflex over (R)} ( f,t ).   (7) [0000] It is noted that whenever the difference between |M(f,t)| and {circumflex over (R)}(f,t) becomes lower than the noise floor, E(f,t) is set to the noise floor. This helps in reducing any artifacts such as musical noise in the RES output. The noise floor can be calculated using any appropriate conventional method, such as a minimum statistics noise estimation technique like the one described in [6]. [0049] The RES output signal component B(f,t) is then generated as: [0000] B ( f,t )= E ( f,t )exp( j φ)   (8) [0000] where φ=∠M(f,t) is the current phase of the AEC output signal. This procedure is performed for the current time period t and all the remaining sub-bands of interest, and the resulting RES output signal components B(f,t) associated with each sub-band are combined in a conventional manner to produce the RES output signal b(t). The net result is to suppress at least part of the echo residual component in the current frame of the AEC output signal. [0050] After the initial frame of the AEC output signal is processed, the foregoing process is repeated for each new frame generated. However, the regression coefficients w i are a function of the room environment and change as the room environment changes. Thus, it is advantageous to update them on a frame-by-frame basis to ensure they more accurately reflect the current conditions. In the embodiment of the present RES system and process employing magnitude as the signal attribute of interest, a magnitude regression-based normalized least-mean squares (NLMS) adaptive algorithm is used, such as described in [5]. However, it is noted that other adaptive algorithms could be used instead, such as recursive least squares (RLS), Kalman filtering or particle filters. [0051] More particularly, before generating the aforementioned RES output for each frame after the initial one, a decision is made as to whether to adaptively update the regression coefficients before moving on. This is done by determining if the current AEC output frame contains near end speech components, using a conventional method such as double-talk detection. If so, the regression coefficients cannot be accurately adapted and the values employed for the current frame are re-used for the next. If, however, near-end speech is absent from the current frame, then the regression coefficients are updated as follows. [0052] First, a smoothed speaker signal power P(f,t) is estimated using a first order infinite impulse response (IIR) filter for the current frame and a particular sub-band f, as: [0000] P ( f,t )=(1−α) P ( f,t− 1)+α∥ X ( f,t )| 2   (9) [0000] where α is a smoothing constant which in tested embodiments was set to a small value, e.g., 0.05 □ 0.1, and where ∥X(f,t)∥ 2 is the energy associated with the speaker signal for the same time period t (e.g., frame) and at the same sub-band. It is noted that in order to improve convergence, P(f,t) is initialized with the energy in the initial frame of the speaker signal. Thus, P(f,0)=∥X(f,1)∥ 2 . In order to prevent the smoothed estimate from attaining a zero value (and thus causing a divide by zero in further computation), a small value can be added to the P(f,t), or if P(f,t) falls below a threshold, P(f,t) can be set to that threshold. These readjustments can be considered to be part of the first-order filter. [0053] The smoothed speaker signal power P(f,t) is used to compute a normalized gradient for the current time period and sub-band under consideration, as: [0000] ∇ ( t ) = - 2  E  ( f , t )   X  ( f , t )  P  ( f , t ) ( 10 ) [0000] This normalized gradient is then used to update the regression coefficients employed in the current frame for the sub-band under consideration. Namely, [0000] w ( t+ 1)= w ( t )−μ∇( t )   (11) [0000] where w(t) is a regression coefficient vector equal to [w 0 w 2 . . . w L-1 ] T for the current time period (e.g., frame) at the sub-band under consideration, and μ is a small step size. The value of μ is chosen so that the residual signal estimate {circumflex over (R)}(f,t) is mostly smaller than |M(f,t)|. In tested embodiments, μ was in a range of 0.0025 and 0.005. In addition, if it is determined that {circumflex over (R)}(f,t) exceeds |M(f,t)|, the step size μ is multiplied by a small factor λ, e.g., 1<λ<1.5. This is to ensure the positivity of E(f,t) as much as possible. RES Process [0054] Referring to FIGS. 3A and 3B , the foregoing RES process can be summarized as follows. First, the current segment (e.g., frame) of the AEC output signal is selected (process action 300 ). In addition, a previously unselected one of the pre-defined sub-bands within a prescribed overall frequency range is selected (process action 302 ). The AEC output signal echo residual component as exhibited in a prescribed signal attribute (e.g., magnitude, energy, and so on) is then predicted in process action 304 using a prescribed regression model (e.g., linear, kernel based regression, and so on) based on a prescribed number of past periods (e.g., frames) of the speaker signal. Next, the prediction results are subtracted from the same attribute of the current AEC output period (e.g., frame) in process action 306 and the noise floor of the current AEC output period is computed in regards to the signal attribute under consideration (process action 308 ). It is then determined if the difference is lower than the noise floor (process action 310 ). If not, the difference is designated as the RES output for the currently selected time period (process action 312 ). However, if the difference is lower, then the noise floor is designated as the RES output for the time period (process action 314 ). A RES output signal component for the selected sub-band and time period is then generated from the designated RES output (process action 316 ). [0055] The process continues in FIG. 3B by first determining if the AEC output associated with the currently selected time period contains near-end speech components (process action 318 ). If not, the smoothed speaker signal power is estimated for the selected time period and sub-band (process action 320 ). This is followed by computing the normalized gradient for the selected time period and sub-band (process action 322 ) and updating the regression coefficients employed in predicting the AEC output signal echo residual component for the selected time period and sub-band (process action 324 ). Once the regression coefficients are updated, or if it was determined in process action 318 that the AEC output associated with the currently selected time period contained near-end speech components, the last computed regression coefficients are designated as the coefficients that are to be used for the associated sub-band to predict the AEC output signal echo residual component for the next time period selected (process action 326 ). [0056] It is next determined if there are any remaining previously unselected sub-bands (process action 328 ). If so, process actions 302 through 328 are repeated until there are no unselected ranges left. The RES output signal components generated for each previously selected sub-band are then combined, and the resulting signal is designated as the RES output signal for the selected period (process action 330 ). At that point, the entire process is repeated for the next time period by repeating process action 300 through 330 as appropriate. Repeated Application of Adaptive RES [0057] Based on the cursory analysis, it can be intuitively presumed that repeated application of RES, will lead to successive reduction in echo residual. This is borne out empirically from experimentation, with a second RES application supplying an echo reduction of about 2-5 dB beyond a first RES application. Thus, when the extra processing time and costs are acceptable it is envisioned that the forgoing RES technique would be run at least twice. This modified RES technique is illustrated in FIG. 4 in an embodiment having two RES stages. As before, the speaker signal x(t) 402 is received and played back in the space represented by near-end block 400 via loudspeaker 404 . The speaker signal playback 406 , as well as the ambient noise n(t) 408 in the near-end space and near-end speech s(t) 410 is picked up by the microphone 412 which produces a microphone signal 414 . This microphone signal 414 is fed into a conventional AEC module 416 , which suppresses a part of the speaker signal playback picked up by the microphone. The output of the AEC module 416 is the aforementioned AEC signal m(t) 418 , which is in turn fed into the first RES module 420 . The first RES module 420 uses this signal and the speaker signal 402 (which is also fed into the AEC module 416 ) to produce the initial RES output signal b(t) 422 in the manner described previously. This initial RES output signal 422 is then fed into a second RES module 424 along with the speaker signal 402 . The second RES module 424 repeats the present RES technique, except using the initial RES output signal b(t) 422 in lieu of the AEC output signal m(t) 418 . The output of the second RES module 424 is the final RES output signal b(t) F 426 . However, as indicated there could also be more than two RES stages (not shown). In that case, additional RES module(s) are added with the output of the immediately preceding RES module being fed into the next module, along with the speaker signal. The final RES output signal is then output by the last RES module in the series. Application to Stereo AEC [0058] The present RES system and process can also be applied to stereo AEC in two ways, both involving two passes of the regression procedure, similar to the repeated application embodiment just described. Stereo AEC has problems with correlations between the right and left channels, however, the present RES approach naturally handles these correlations by removing them in two passes. Essentially, there is no difference in the processing itself, only a difference in which signals are input to the RES modules. In the first approach illustrated in FIG. 5 , the present RES technique is applied to the AEC output based on the left channel speaker signal x L (t) 506 in the first pass, and then the right channel speaker signal x R (t) 502 in the second pass. More particularly, the right channel speaker signal x R (t) 502 is received and played back in the space represented by near-end block 500 via loudspeaker 504 , while the left channel speaker signal x L (t) 506 is received and played back in the space via loudspeaker 508 . The right and left channel far end signal playbacks 510 , 512 , as well as the ambient noise n(t) 514 in the near-end space and near-end speech s(t) 516 are picked up by the microphone 518 , which produces a microphone signal 520 . This microphone signal 520 is fed into a conventional stereo AEC module 522 , along with both the right and left channel speaker signals 502 , 506 . The stereo AEC module 522 suppresses a part of the left and right speaker signal playback picked up by the microphone 518 . The output of the AEC module 522 is the AEC signal m(t) 524 , which is in turn fed into the first RES module 526 . The first RES module 526 uses this signal and the left channel speaker signal x L (t) 506 to produce the first RES output signal b 1 (t) 528 in the manner described previously. This first RES output signal 528 is then fed into a second RES module 530 along with the right channel speaker signal 502 . The second RES module 530 repeats the present RES technique, except using the first RES output signal b 1 (t) 528 in lieu of the AEC output signal m(t) 522 . The output of the second RES module 530 is the final RES output signal b(t) F 532 . This method is also applicable to multi-channel playback where the number of playback channels is greater than 2 (e.g. 5.1, 7.1, and so on). [0059] In the second approach illustrated in FIG. 6 , the present RES technique is applied to the stereo AEC output based on the sum of the left and right channel speaker signals in the first pass and on the difference between the left and right channel speaker signals in the second pass. More particularly, as in the first embodiment, the right channel speaker signal x R (t) 602 is received and played back in the space represented by near-end block 600 via loudspeaker 604 , while the left channel speaker signal x L (t) 606 is received and played back in the space via loudspeaker 608 . The right and left channel speaker signal playbacks 610 , 612 , as well as the ambient noise n(t) 614 in the near-end space and near-end speech s(t) 616 are picked up by the microphone 618 which produces a microphone signal 620 . This microphone signal 620 is fed into a conventional stereo AEC module 622 , along with both the right and left channel speaker signals 602 , 606 . The stereo AEC module 622 suppresses a part of the left and right speaker signal playback picked up by the microphone 618 . The output of the AEC module 622 is the AEC signal m(t) 624 , which is in turn fed into the first RES module 626 . In addition, the right and left channel speaker signals 602 , 606 are summed in summing module 634 and the resulting summed signal 636 is fed into the first RES module 626 . The first RES module 626 uses the AEC signal m(t) 624 and the summed channel signal 636 to produce the first RES output signal b 1 (t) 628 in the manner described previously. This first RES output signal 628 is then fed into a second RES module 630 . In addition, the right and left channel speaker signals 602 , 606 are subtracted in the difference module 638 and the resulting difference signal 640 is fed into the second RES module 630 . The second RES module 630 uses the first RES output signal b 1 (t) 628 and the difference signal 642 to produce the final RES output signal b(t) F 632 in the manner described previously. [0060] It is noted that the order in which the left and right channel far end signals are processed in the RES modules in the first stereo RES embodiment or the order in which the summed and difference signals are processes in the RES modules in the second stereo RES embodiment could be reversed from that described above if desired. 3.0 References [0000] [1] G. Enzner, R. Martin and P. Vary, “Unbiased residual echo power estimation for hands free telephony”, ICASSP '02, pp. 1893-1896, Orlando, Fla., May 2002. [2] M. Kallinger and K. Kammeyer, “Residual echo estimation with the help of minimum statistics”, IEEE Benelux Signal Processing Symposium, Leuven, Belgium, March 2002. [3] K. Lebart, et. al., “A New Method Based on Spectral Subtraction for the Suppression of Late Reverberation from Speech Signals”, Audio Engineering Society Issue 4764, 1998. [4] J-M. Jot, et. al., “Analysis and Synthesis of Room Reverberation Based on a Statistical Time-Frequency Model”, Audio Eng. Soc. 103rd Convention, New York, 1997. [5] S. Haykin, “Adaptive Filter Theory”, Prentice Hall, 4th Edition, September 2001. [6] R. Martin, “Spectral subtraction based on minimum statistics,” Proc. EUSIPCO-94, pp. 1182-1185, Edinburgh, 1994.
A regression-based residual echo suppression (RES) system and process for suppressing the portion of the microphone signal corresponding to a playback of a speaker audio signal that was not suppressed by an acoustic echo canceller (AEC). In general, a prescribed regression technique is used between a prescribed spectral attribute of multiple past and present, fixed-length, periods (e.g., frames) of the speaker signal and the same spectral attribute of a current period (e.g., frame) of the echo residual in the output of the AEC. This automatically takes into consideration the correlation between the time periods of the speaker signal. The parameters of the regression can be easily tracked using adaptive methods. Multiple applications of RES can be used to produce better results and this system and process can be applied to stereo-RES as well.
7
CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of Provisional Application No. 60/536,082, filed Jan. 13, 2004, entitled “Device for Sealing Foodstuff Containers and Foodstuff Container Provided with such a Device”. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates to a device for sealing foodstuff containers, in particular drink containers, comprising: a sealing element adapted to engage on a wall of a foodstuff container around a wall opening arranged in the wall, and an operating element adapted to co-act with the sealing element for displacing the sealing element between an opened position leaving the wall opening clear and a closed position sealing the wall opening, the operating element being provided with coupling means for coupling to the foodstuff container, wherein the relative orientation of the sealing element and the operating element can be changed such that the operating element can cause the sealing element in the closed position to engage under bias on the wall for substantially medium-tight sealing of the foodstuff container. The invention also relates to a foodstuff container provided with such a device. [0004] 2. Description of Related Art [0005] Reclosable liquid containers have already been known for a long time. The American patent specification U.S. Pat. No. 4,077,538 thus describes a reclosable can for drinks or other foodstuffs. The known can is closed at the top by a seam-folded upper wall or cover. The upper wall is herein provided with a wall opening for passage of drink held in the can. The can is further provided with a device connected to the upper wall for closing the can. The device herein comprises a rotatable sealing element and a standing operating element connected to the sealing element. The sealing element is preferably constructed from a non-permeable lip which, after rotation of the operating element, can cover or leave clear the wall opening whereby the passage of drink can thus be respectively prevented or made possible. The advantage of the known can is that the can is reclosable, whereby the content of the can does not have to be consumed all at once but can, if desired, be consumed in portions at different times. Closing the passage opening of the can by means of the lip does somewhat enhance conservation of the content of the can, but mainly prevents the content of the can leaving or being able to leave the can in simple manner. As well as the above stated advantage, the known can also has drawbacks. A significant drawback of the known can is that only mediocre sealing of the can is realizable. The sealing element cannot seal the can completely in liquid-tight manner, or can do so only briefly. In the sealing situation of the can the content of the can is however still accessible to micro-organisms and gas exchange can take place freely between the atmosphere surrounding the can and the local atmosphere prevailing in the can. Particularly when the drink held in the can is carbonated, whereby an internal pressure will be built up in the can, the sealing element will be unable to seal the can sufficiently, as a result of which the carbon dioxide can and will escape. As already generally known, a reduction in the carbon dioxide content of drink results in a—usually unwanted—change in the taste of this drink. [0006] An improved device for sealing beverage containers, in particular beverage containers filled with a carbonated beverage, is disclosed in the American patent specification U.S. Pat. No. 6,626,314. This device comprises an operating element and a sealing element which are mutually coupled by means of a screw connection via a central wall opening in the wall of the beverage container. By rotating the operating element the sealing element can be lowered or raised thereby clearing respectively blocking another wall opening to open respectively seal the beverage container. Although with the known device a significantly improved closure for (carbonated) beverage containers is provided, the known device also has multiple drawbacks. A first major drawback of the device is that the device is constructively relatively complex. Due to this constructive complexity the prime costs to manufacture the known device are commonly considerable. Moreover, since the top wall of the beverage container is provided with multiple wall openings the device is relatively sensitive for leakage and which is to the prejudice of the reliability of the known device. SUMMARY OF THE INVENTION [0007] The invention has for its object, while retaining the above stated advantage of the prior art, to provide a relatively simple device for sealing a foodstuff container, using which the foodstuff container can be sealed reliably in a substantially medium-tight manner. [0008] The invention provides for this purpose a device for sealing foodstuff containers with the feature that said coupling means being adapted to engage on a peripheral edge of the wall opening around which the sealing element may engage under bias. By adapting the device according to the invention to a single wall opening, instead of to multiple wall openings, a relatively simple device can be obtained, which can be manufactured in a relatively simple and inexpensive manner. Since the single joint (or common) wall opening has a multilateral functionality, whereas the same wall opening is adapted for both passage of foodstuff on one side and for passage of a part of the operating element to allow coupling of the device to the foodstuff container, a relatively efficient device is provided. Moreover, since the single, joint (or common) wall opening is applied, instead of the application of multiple wall openings, the risk of leakage is reduced considerably, thereby making the device relatively suitable and reliable to be applied in combination with beverage containers containing carbonated beverages. The coupling means can be formed for instance by a projecting flange adapted to engage on a side of the wall remote from another part of the operating element. However, preferably the coupling means comprises multiple resilient lips to achieve a solid connection between the operating element and the wall of the foodstuff container. The operating element will thus be partially situated in the wall opening such that the operating element engages bilaterally on the wall. The projecting flange(s) herein lock(s) the mutual position of the operating element relative to the wall. The flange(s) can herein engage on a part of the peripheral edge of the wall opening or can be positioned along the whole peripheral edge of the wall opening. Besides application of the single multifunctional joint wall opening, it is still important that sealing element engages under bias on the wall of the foodstuff container (provided with the wall opening). By causing the sealing element to engage under bias on the wall of the foodstuff container, the foodstuff container is sealed in substantially medium-tight manner. This not only prevents the possibility of the liquid and/or solid foodstuff leaving the foodstuff container in the closed position of the foodstuff container, but also prevents gas exchange being able to take place between an atmosphere surrounding the foodstuff container and an atmosphere prevailing in the foodstuff container. In the case the foodstuff is formed by a carbonated drink, the carbon dioxide will remain confined in the foodstuff container in the closed situation, whereby it will also be possible to maintain the carbon dioxide content in the foodstuff container, which enhances the preservation of taste and the like. Using a device according to the invention it is moreover possible to prevent micro-organisms being able to move, in the closed situation, from outside the foodstuff container to a location inside the foodstuff container. A constant composition of the foodstuff can therefore be guaranteed with the device according to the invention in closed position, wherein the foodstuff can also be conserved in relatively hygienic manner in the closed foodstuff container. In the opened situation of the sealing element, the sealing element is generally situated substantially at a distance from the wall, whereby removal of foodstuff along the sealing element and via the wall opening can take place freely and preferably unimpeded. After sufficient removal of the foodstuff, the sealing element can be displaced once again to the closed position, wherein a bias will be exerted directly or indirectly on the wall in order to realize the medium-tight sealing of the foodstuff container. The bias exerted on the wall by the sealing element can be adjusted in discrete or continuous manner by means of the operating element for a user. [0009] The sealing element and the operating element can be located substantially on one side relative to the wall, but the sealing element and the operating element are preferably adapted to mutually enclose a part of the wall of the foodstuff container. The operating element generally has to be readily accessible to the user and will usually be positioned substantially on an outer side of the wall. The sealing element is preferably located at least substantially inside the foodstuff container. In this manner it is possible to prevent, or at least counter, the sealing part—usually a sealing edge—of the sealing element becoming dirty relatively easily, which is often at the expense of the reliability of the medium-tight sealing. [0010] After removal of a quantity of foodstuff out of the foodstuff container commonly a residue of foodstuff remains within the single multi-purpose wall opening by sticking to the edge of the wall opening, which could easily lead to unhygienic situations. To prevent remaining of a foodstuff residue within the wall opening, the sealing element is preferably designed such that the sealing element is positioned partially within the wall opening in the closed position of the sealing element thereby pushing this residue out of the wall opening. The operating element is preferably provided with a passage opening for the foodstuff held in the foodstuff container. From a hygienic viewpoint the passage opening can more preferably be sealed by a screening element forming part of the sealing element and projecting in the direction of the operating element. This applies particularly in the case liquid foodstuffs, in particular drinks, are held in the foodstuff container. This screening element is preferably congruent to the passage opening formed in the operating element. To facilitate direct consumption of the foodstuff, both the passage opening and the screening element are preferably substantially reniform (or kidney) shaped. The passage opening bounded by the operating element will then generally result in an improved sensation the user when the drink is consumed directly from the foodstuff container, since the operating element—generally manufactured from plastic—will provide a better sensation than the generally sharp peripheral edge of the wall opening. Furthermore, injuries to the user resulting from cuts from the peripheral edge can thus be prevented, or at least countered. [0011] In a preferred embodiment the mutual distance between the sealing element and the operating element can be changed. The mutual co-action of the sealing element and the operating element is herein such that, in the case of translation and/or rotation of the operating element in the closed situation of the device, the sealing element will displace in a direction away from the operating element. In a closed position the sealing element will then rest under bias against the wall around the wall opening, and in an opened position the sealing element will be positioned at least partially, but preferably wholly at a distance of the wall. Because the operating element—after mounting on a foodstuff container—will be coupled by means of coupling means to the foodstuff container, preferably to the wall, the possibility for translation of the operating element relative to the foodstuff container will generally be limited, and will usually even be minimized and become zero. In that case the operating element will only be rotatable relative to the wall. After rotation of the operating element relative to the wall and the sealing element, the sealing element will hereby be forced to displace relative to the wall and the operating element. It is noted that foodstuff container should be interpreted in a broad sense. Understood here are all kinds of conventional containers and packages which are used to conserve foodstuffs. The foodstuffs can herein be formed by (carbonated) drinks, syrups, tablets, sweets, consumable sprinkling materials, etc. [0012] The sealing element preferably engages via a seal on the wall of the foodstuff container which is provided with the wall opening, in the closed position of the sealing element. In order to guarantee the medium-tight sealing in the closed situation of the device, a sealing layer will be advantageous. The seal will generally be formed by a flexible, sealing strip of material which is arranged on a part of the sealing element that is adapted to support under bias on the wall. It is also possible to envisage arranging the sealing strip of material on the wall itself at the location where the sealing element will support in the closed situation. Preferably, the sealing strip is provided with a projecting flange to give the sealing strip a non-planar geometry. It has been found that in this manner, an improved sealing effect can be obtained with the non-planar strip. Various conventional materials can be applied as sealing material. Preferably used is a thermoplastic rubber (TPR), such as a thermoplastic elastomer (TPE), and/or a flexible foam with a closed cell structure. Examples of applicable materials are: ethylene vinyl acetate rubber (EVA), ethylene vinyl ethanol (EvOH) and silicone rubber. The operating element and a remaining part of the sealing element may be made of plastic, such as polyethylene (PE) and polypropylene (PP). [0013] In a preferred embodiment the sealing element engages under bias on, or at least near, a peripheral edge of the wall of the foodstuff container provided with the wall opening in the closed position of the sealing element. In this manner the actual seal is not formed directly around the wall opening, but rather at or at least near the peripheral edge of the wall containing said opening. In this manner a stable, reliable seal can be obtained by means of the device according to the invention, while maintaining a relatively simple construction. [0014] The coupling between the operating element and the sealing element can be of various nature. However, preferably the operating element and the sealing element are mutually coupled by means of a threaded connection. When the relative orientation of the sealing element and the operating element is changed, the mutual distance of the two components will thus also be changed. In addition to screw (thread) connections, the use of other types of co-acting connections can also be envisaged, such as for instance a bayonet connection (bayonet fitting). In a particular preferred embodiment the threaded connection is substantially enclosed by the sealing element and at least one of the wall of the food container and the operating element, at least in the closed position of the sealing element. In this way, fouling of the threaded connection by residue(s) of the foodstuff can be prevented, as a result of which unhygienic situations and malfunctioning of the threaded connection can be prevented. Optionally, at least a part of the threads of the threaded connection is interrupted to allow conditionally a certain degree of venting, in particular de-aeration, between the space within the foodstuff container and the surrounding atmosphere. [0015] In another preferred embodiment the sealing element is provided with at least one receiving space for a pin projecting from the wall. The pin preferably projects in the direction of a space enclosed by the foodstuff container, so as to minimize the number of components protruding in the direction of the user. The pin is preferably formed by a cylindrical body, but can optionally also be designed in another manner. More preferably, the pin is provided with a elongated flattened part for facilitating receipt of the pin by the (substantially cylindrical) receiving space, since liquids eventually contained within the receiving space can be removed relatively easily when receiving the pin. The mutual co-action of the pin and the receiving space prevents rotation of the sealing element. The sealing element is however displaceable along the pin, whereby translation of the sealing element relative to the wall and the operating element, for instance after rotation of the operating element, remains possible. The pin can be formed by a bent and/or folded part of the wall, but may also form part of an intermediate element, for instance a stationary intermediate ring, placed separately between the sealing element and the operating element. The intermediate ring is then preferably connected fixedly to the wall, wherein the pin preferably projects via the wall opening in the direction of the sealing element. To this end, the intermediate ring can be attached by means of injection moulding directly onto the (aluminium) wall of the foodstuff container. The advantage of the intermediate ring is that the existing structure of a conventional foodstuff container need not be changed in order to apply the pin in order to prevent rotation of the sealing element. It is then possible to suffice with an intermediate ring or other type of intermediate element separately manufactured and arranged at a later stage. In order to further stabilize prevention of rotation of the sealing element, a plurality of (spaced-apart) projecting pins may be applied. Preferably, the intermediate ring is provided with a guiding projecting flange to facilitate removal of foodstuff out of the foodstuff container. [0016] The operating element is preferably provided with a projecting engaging member for a user. The projecting engaging member generally facilitates opening and respectively closing of the foodstuff container. The engaging member is preferably formed by a fin-like member. This fin-like member is more preferably slightly curved to facilitate a user to engage the operating element. In addition to serving as a handle, the projecting member can also serve to bound the maximum rotation of the operating element, since in particular foodstuff containers, such as drink cans, the wall opening is arranged asymmetrically in the wall, wherein after a determined rotation the projecting engaging member will engage on a seam-folded part of the wall, whereby further rotation of the operating element can be prevented. An outer edge of the operating element can also be given a profiled form, whereby this outer edge can effectively also function as engaging member for the user. Preferably, substantially all tactile edges and other pointed parts of the operating element, in particular the engaging member, are rounded to prevent injuries by a user, in particular children, when operating the device according to the invention. [0017] The foodstuff container is adapted to contain various kinds of foodstuffs. Certain foodstuffs, such as carbonated beverages, build up pressure within the food container in closed state. To facilitate opening of the pressurized food container, the device is preferably provided with venting means in particular for de-aeration of the foodstuff container via the wall opening. After this de-aeration the device and hence the food container can be opened relatively easily. Particularly in the case of liquid foodstuffs, usually drinks, a venting opening will also be advantageous, particularly during removal of the drink from the drink container. Gurgling removal of drink can thus be prevented, or at least countered. Since de-aeration also occurs via the (joint) wall opening, the wall opening obtains an additional functionality. It may be clear that the venting means can also be used for aeration, instead of de-aeration, of the food container, which may be conceivable in case a vacuum fraction is present within the food container. Preferably, the venting means comprises a first venting member making part of the operating element and a second venting member making part of the sealing element, said second venting member being adapted to co-act with the first venting member such that the mutual orientation of the first venting member and the second venting member can be changed to allow venting respectively block venting through the venting means. Commonly, the first venting member and the second venting member are mutually rotatable, wherein one venting member surrounds the other venting member. Both venting members are commonly provided with a flattened part. In that case, venting is solely possible in case both flattened parts are positioned in line, or are at least positioned such that both flattened parts are in mutual communication. [0018] In a preferred embodiment the device is initially sealed in the closed situation of the device. In this manner a user can ascertain at the time of purchase whether the foodstuff container has previously been (improperly) opened, and whether the content corresponds to a content with specific quality standards guaranteed by the manufacturer. In a particular preferred embodiment the tamper-evident seal is formed by a mutual breakable connection between the sealing element and the operating element. The connection can for instance be formed by a rod and/or by a hook-shaped member. Said hook-shaped member is preferably applied in or near the wall opening to prevent or counter any tampering with the device, wherein the hook-shaped member may be coupled to both an upper surface of the sealing element and a lower surface of the operating element. Besides the functionality as tamper-evident seal, the hook-shaped member can subsequently be used to close the device in a locked member, by fixing the mutual orientation of the operating element and the sealing element. In this latter case, the device can merely be opened by firstly de-hooking the operating element relative to the sealing element. The seal is more preferably visible to the user, so that the user can see at a glance whether or not the device has been opened at an earlier stage. In a particular preferred embodiment, the rod is initially connected to the peripheral edge of the venting opening incorporated in the operating element. The rod is thus visible to the user. During initial opening of the device the rod will be permanently detached from the peripheral edge, whereby the seal is visibly broken and wherein the venting hole can actually function as aeration and venting of the foodstuff container. [0019] In a preferred embodiment the operating element can be fixed relative to the top element in at least one preferred position, in which the sealing element, co-acting with the operating element, is at least substantially situated in the closed position. The device can thus be closed in locked manner, whereby undesired and unexpected changes of the relative orientation of the sealing element and the operating element from a closed position to an open position can be prevented. The device according to the embodiment can thus not be opened in uncontrolled manner by for instance a (slight) external load, but only by one or more controlled operations, which are performed—in an optionally specific sequence—by a user. If the user fixes the relative orientation of the operating element and the sealing element, further removal of the foodstuff, such as a beverage, from the device will thus only be possible after release of the sealing element fixed relative to the operating element. It is also conceivable that other states of the device, besides the closed state, may be lockable. It is therefore for example imaginable that the open state of the device is also lockable, or at least restricted, to prevent excessive opening of the device, which could lead to malfunctioning of the device. [0020] The sealing element is preferably provided with reinforcement means. The reinforcement means preferably comprises a single or multiple reinforcement ribs, thereby each rib extending in a radial direction of the sealing element. In this manner, the sealing element is provided sufficient strength and stiffness to resist internal pressures more than 7 bar. Moreover, the ribs can be used as gate during manufacturing of the sealing element by injection moulding. [0021] In another preferred embodiment the device is provided with barrier means for substantially preventing scouring water and other compounds to enter the foodstuff container in the closed position of the sealing element. During manufacturing of the assembly of the foodstuff container and the device commonly the assembly is cleaned by scouring water. Moreover, the foodstuff contained by the foodstuff container is often pasteurised by the (hot) scouring water. To prevent the scouring water from entering the assembly, the barrier means are provided. This barrier means may be formed e.g. by a rubber strip, e.g. made of TPE or TPR, or by a labyrinth. Preferably, the operating element and the barrier means as a two-components-system is preferably manufactured in a single process step by particular injection moulding. Commonly, this barrier means is applied after filling of the container and before pouring or pasteurising (the content of) the container. [0022] The invention also relates to a foodstuff container provided with such a device according to the invention. As already noted, the device can be applied in diverse types of (substantially) conventional foodstuff container. The device is preferably positioned in an upper wall of the foodstuff container, since removal of the relevant foodstuff generally takes place via the upper wall of the foodstuff container. The foodstuff container is preferably formed by a drink container such as, for instance, a bottle, carton or can. In a drink container the wall opening through which the drink can be removed is generally also situated on the upper wall, or at least one of the upper walls of the relevant drink container. The device will usually already be connected to the upper wall during the manufacturing process of the relevant drink container. During manufacture of a drink can, a cover will first of all be provided with the device according to the invention, before the cover is seam-folded onto a body filled with drink. BRIEF DESCRIPTION OF THE DRAWINGS [0023] The invention will be elucidated on the basis of the non-limitative embodiments shown in the following Figs. herein: [0024] FIG. 1 a shows a perspective view of a device for closing a foodstuff container according to the invention. [0025] FIG. 1 b shows a semi-transparent, perspective top view of the device according to FIG. 1 a. [0026] FIG. 1 c is a semi-transparent, perspective bottom view of the device according to FIGS. 1 a and 1 b. [0027] FIG. 1 d is a semi-transparent side view of the device according to FIGS. 1 a - 1 c. [0028] FIG. 2 a shows a perspective view of another device according to the invention in the closed situation. [0029] FIG. 2 b shows a perspective view of the device according FIG. 2 a in the opened situation. [0030] FIG. 2 c is a perspective top view of the device according to FIGS. 2 a and 2 b in closed situation. [0031] FIG. 3 a shows a perspective cross-section of an alternative device according to the invention in closed situation. [0032] FIG. 3 b shows a perspective cross-section of the device according to FIG. 3 a in opened situation. [0033] FIG. 3 c is a perspective bottom view of the device according to FIGS. 3 a and 3 b in closed situation. [0034] FIG. 3 d is a perspective top view of the device according to FIGS. 3 a - 3 c in closed situation. [0035] FIG. 4 shows a schematic cross-section of a soft drink can provided with a device according to the invention. [0036] FIG. 5 a shows a perspective view of an assembly of a wall of a beverage can and a part of a device according to the invention. [0037] FIG. 5 b shows a perspective view of an upper side of a complementary part of the device shown in FIG. 5 a. [0038] FIG. 5 c shows a perspective view of a bottom side the complementary part shown in FIG. 5 b. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0039] FIG. 1 a shows a perspective view of a device 1 for closing a foodstuff container (not shown) according to the invention in closed situation. The device 1 comprises a sealing element 2 and an operating element 3 connected rotatably to sealing element 2 . Sealing element 2 is adapted to be positioned inside the foodstuff container, and operating element 3 (for a user) is adapted to be positioned outside the foodstuff container. Sealing element 2 and operating element 3 mutually co-act by means of a screw thread connection (see FIGS. 1 b - 1 d ). The mutual distance between operating element 3 and sealing element 2 can be changed by means of rotating the operating element 3 relative to sealing element 2 . In order to prevent simultaneous rotation of sealing element 2 during rotation of operating element 3 , sealing element 2 is locked two-dimensionally by means of two stationary pins (see FIGS. 1 c and 1 d ). The pins herein form part of an intermediate ring (see FIGS. 1 c and 1 d ). Sealing element 2 is provided for this purpose with two receiving spaces 4 for the two pins. Operating element 3 is provided with a projecting coupling flange 5 for clamping the operating element 3 in a wall opening of the foodstuff container. Operating element 3 is provided with a moon-shaped passage opening 6 for the foodstuff held in the foodstuff container. In the shown closed situation of device 1 , the passage opening is filled by a likewise moon-shaped projection 7 in order to enable hygienic sealing of the space situated below operating element 3 . Operating element 3 is provided with a fin-like projection 8 to facilitate rotation of operating element 3 by the user. In the shown situation the device 1 is closed, whereby removal of foodstuff from the foodstuff container will not be possible. After arranging the shown device 1 on the wall of the foodstuff container, an edge 9 forming part of sealing element 2 will support under bias on the wall, whereby a medium-tight sealing of the foodstuff container can be realized. In the shown device 1 however, there is no physical contact present between the edge 9 of sealing element 2 and the wall, since a sealing layer 10 is arranged between the two. This layer 10 can be fixed by means of an adhesive to the wall or to the edge 9 of sealing element 2 . Operating element 3 is provided with a venting opening 11 in order to facilitate removal of—particularly liquid—foodstuff. In venting opening 11 a free end of a rod 12 connected to sealing element 2 is now visible. The rod will break and/or deform permanently once the operating element 3 is rotated relative to sealing element 2 . Rod 12 therefore functions in fact as an indicator of whether the device 1 is still sealed or not. Device 1 is arranged in the shown situation on the foodstuff container and marketed commercially as an assembly. Device 1 is preferably manufactured wholly, or in any case at least partially, from plastic. It is also conceivable to manufacture the device 1 from a different material, such as for instance metal. [0040] FIG. 1 b shows a semi-transparent perspective top view of the device 1 of FIG. 1 a. In the present view the operating element 3 is shown semi-transparently. The other components are shown in the normal situation of device 1 . FIG. 1 b shows clearly that the sealing element is provided with a centrally located tubular member 11 provided with an internal screw thread 12 . The tubular member 11 is also provided with a protrusion 13 located at a distance from screw thread 12 for the purpose of bounding the maximum relative rotation of operating element 3 and sealing element 2 . In the present embodiment the maximum angle of rotation amounts to (substantially) 120°. An opposite boundary of this maximum angle of rotation is formed by the moon-like projection 7 , which is bounded in the closed situation by mutual co-action with passage opening 6 . The mutual distance between screw thread 12 and protrusion 13 is here minimally the wall thickness of a projecting tubular member which forms part of operating element 3 and which is provided with an external screw thread (see FIG. 1 c ). Also shown clearly in FIG. 1 b is the intermediate ring 14 , which is positioned concentrically relative to sealing element 2 . The intermediate ring 14 is usually manufactured from plastic and is generally connected fixedly to the wall of the foodstuff container. [0041] FIG. 1 c shows a semi-transparent, perspective bottom view of the device 1 of FIGS. 1 a and 1 b. In FIG. 1 c the sealing element 2 is shown semi-transparently. The other components of device 1 are however shown normally. In the present Fig. the projecting tubular body 15 forming part of operating element 3 is clearly shown. The body 15 is herein provided with an external screw thread 16 and is provided on an inner side with a projecting counter-protrusion 17 . Screw thread 16 is adapted to co-act with the screw thread 12 forming part of sealing element 2 . The counter-protrusion 17 is herein adapted to co-act with the protrusion 13 forming part of sealing element 2 , as already stated above. The intermediate ring 14 is now also clearly shown, wherein the intermediate ring is provided with the above mentioned pins 18 . Pins 18 are herein received in the receiving spaces 4 of sealing element 2 , whereby only one-dimensional displacement of sealing element 2 is possible during rotation of operating element 3 . [0042] FIG. 1 d shows a semi-transparent side view of the device 1 of FIGS. 1 a - 1 c . Sealing element 2 is once again shown semi-transparently. The wall of the foodstuff container is now shown by means of a broken line 19 . After rotation of operating element 3 , sealing element 2 will be displaced linearly along the pins 18 in a (downward) direction away from operating element 3 , whereby sealing element 2 comes to lie at a distance from wall 19 . In this opened situation the foodstuff can be removed along the sealing element and via the wall opening (not shown). In an alternative embodiment the pins 18 are formed integrally by a deformed part of the wall of the foodstuff container. Pins 18 can thus be formed by downward deformation of (punched) parts of the foodstuff container, whereby a passage opening for the foodstuff is also provided situated between pins 18 . [0043] FIG. 2 a shows a perspective view of another device 20 according to the invention in the closed situation. The operation very largely corresponds with the operation of the device 1 shown in FIGS. 1 a - 1 d . Device 20 comprises a top element 21 , an intermediate layer 22 rotatably connected to top element 21 , and a cover element 23 co-acting with top element 21 and intermediate layer 22 . Arranged between intermediate layer 22 and cover element 23 is a sealing ring 24 , which is connected to intermediate layer 22 . Cover element 23 is provided with a receiving opening 25 for a pin 26 forming part of intermediate layer 22 . Top element 21 is provided with a handgrip 27 and a profiled edge 28 to facilitate rotation of top element 21 . Top element 21 is also provided with a venting opening 29 in which a flexible rod-like member 30 is received in the closed situation. The rod-like member 30 in fact seals the venting opening 29 in the closed situation. When top element 21 is rotated relative to intermediate layer 22 and cover element 23 , the rod-like member 30 will be removed from venting opening 29 . The cover element will simultaneously be displaced linearly along the pin 26 , whereby removal of the relevant foodstuff, usually drink, from the foodstuff container can take place along cover element 23 and via intermediate layer 22 and a passage opening 32 arranged in top element 21 (see FIG. 2 b ). [0044] FIG. 2 b shows a perspective view of the device 20 of FIG. 2 a in the opened situation. FIG. 2 b shows clearly that top element 21 and cover element 23 are located a distance from each other, whereby removal of foodstuff from the foodstuff container can take place (see arrow A). Also shown is that rod-like member 30 , temporarily deformed, rests against an underside of top element 21 until top element 21 is rotated back to the situation shown in FIG. 2 a , after which the rod-like member 30 will once again extend into venting opening 29 . [0045] FIG. 2 c shows a perspective top view of the device 20 of FIG. 2 a and 2 b in closed situation. In the closed situation the passage opening 32 is sealed by means of a raised part 33 forming part of cover element 23 . Also shown is that handgrip 27 is provided with an eye 34 which co-acts with an elevated member 35 arranged in intermediate layer 22 . The elevated member 35 prevents the top element 21 from being able to rotate in undesired and simple manner. Only after overcoming a determined bias can the eye 34 be carried over the elevated member 35 , whereafter unimpeded rotation of top element 21 through a determined angle is made possible. Top element 21 can in fact therefore be locked in the closed position of device 20 . [0046] FIG. 3 a shows a perspective cross-section of an alternative device 36 according to the invention in closed situation. Device 36 is arranged on a cover 37 of a drink can. Device 36 comprises an internal element 38 and an external element 39 co-acting with internal element 38 . Internal element 38 is provided for this purpose with a cylindrical member 40 provided with an internal screw thread 41 , and external element 39 is likewise provided with a cylindrical member 42 provided with an external screw thread 43 . Rotation of internal element 38 is prevented by locking of internal element 38 on one side. The one-sided locking is realized by mutual co-action of an irregular portion 44 arranged in cover 37 on the one hand and two fixation protrusions 45 forming part of internal element 38 and engaging on either side on the irregular portion 44 on the other. A part of external element 39 is arranged with clamp fitting in a passage opening for drink arranged in cover 37 . External element 39 herein engages on cover 37 on two sides. External element 39 is provided for this purpose with a projecting flange 46 for engaging on the inner side of cover 37 , and a supporting edge 47 for engaging on an outer side of cover 37 . External element 39 is also provided with a drinking opening 48 for a user, which drinking opening 48 is filled in the shown, closed situation by a plunger member 49 forming part of internal element 38 . In the shown situation a sealing edge 50 forming part of internal element 38 engages under bias on cover 37 . A sealing edge (not shown) is preferably arranged between sealing edge 50 and cover 37 in order to ensure a long-term medium-tight sealing of the drink can. When external element 39 is rotated, internal element 38 will move linearly in a direction away from cover 37 , whereafter sealing edge 50 also comes to lie at a distance from cover 37 , whereby the can is thus opened and removal of drink is made possible. This opened situation is shown in FIG. 3 b . In the shown situation the maximum rotation of external element 39 has been reached, as a lip 51 forming part of external element 39 engages on an edge 52 forming part of cover 37 . FIG. 3 b also shows that plunger member 49 of internal element 38 has a surface with an inclining orientation relative to a remaining part of device 36 . The higher situated part of plunger member 49 herein forms a boundary to excessive rotation of external element 39 in the direction of the closed position as shown in FIG. 3 a. [0047] FIG. 3 c shows a perspective bottom view of device 36 of FIGS. 3 a and 3 b in closed situation. FIG. 3 c shows in particular the mutual co-action of the irregular portion 44 and the fixation protrusions 45 enclosing the irregular portion 44 , whereby rotation of internal element 38 relative to cover 37 and external element 39 can be prevented. [0048] FIG. 3 d shows a perspective top view of device 36 of FIGS. 3 a - 3 c in closed situation. Passage opening 48 of external element 39 is now filled by plunger member 49 . FIG. 3 d also shows that external element 39 is provided with venting opening 53 to make it possible to prevent gurgling removal of drink. External element 39 is moreover provided with a profiled edge 54 to facilitate rotation of external element 39 for the user. [0049] FIG. 4 shows a schematic cross-section of a soft drink can 55 provided with a device 56 according to the invention. Can 55 is filled with a carbonated soft drink 56 . Can 55 is constructed from a base element 57 , a body 58 connected to base element 57 and a cover 59 seam-folded round body 58 . Cover 59 is provided with a passage opening 60 for drink. Device 56 is coupled to cover 59 and is adapted for renewed medium-tight sealing of cover 59 . Cover 59 comprises for this purpose a guide means 61 connected fixedly to cover 59 and provided with a receiving space 62 for a slide 63 connected in guiding manner to guide means 61 . Slide 63 is coupled by means of a flexible element 64 to a sealing element 64 located in can 55 . By sliding the slide 63 along guide means 61 (arrow A) and positioning it on receiving space 62 , sealing element 64 can be pulled firmly against cover 59 (arrow B) such that a medium-tight sealing is created. Cover 59 is however now provided with a rubber ring 65 to ensure the medium-tight sealing. So as to stabilize the position of sealing element 64 to some extent, cover element 64 is provided with a pin 66 which protrudes with clamp fitting through an opening 67 arranged in cover 59 . A seal 68 is likewise arranged between pin 66 and opening 67 . In order to facilitate displacement of slide 63 , this latter is provided with a handgrip 69 . [0050] FIG. 5 a shows a perspective view of an assembly 70 of a wall 71 of a beverage can and a part of a device 72 according to the invention. The shown part of the device 72 comprises an operating element 73 provided with an external screw thread 74 . The shown part of the device 72 further comprises an intermediate ring 75 provided with two pins 76 extending downwards. Both the operating element 73 and the ring 75 are adapted to be coupled to a sealing element 77 as shown in FIGS. 5 b and 5 c . The ring 75 is provided with a rounded edge thereby forming a flange to optimise the sealing capacity of the ring 75 . The operating element 73 further comprises a protruding pen 78 provided with a flattened part 79 , said pen 78 being adapted to block or clear a venting passage 80 enclosed by the sealing element 77 . Said protruding pen 78 may alternatively be provided with a groove instead of a flattened part. As is shown in FIG. 5 b , the sealing element 77 comprises a protruding hollow cylindrical body 81 adapted to receive said pen 78 . Said hollow body 81 is provided with a recess 82 to allow de-aeration of the beverage can via the flattened part 79 of said pen 78 . To secure substantially free, unhindered flow of gas during de-aeration of the beverage can an inner screw thread 83 of the sealing element 77 is interrupted. The sealing element 77 also comprises two slots 84 for receiving the pins 76 of the intermediate ring 75 . The sealing element 77 is provided with a sealing ring 86 to secure medium-tight engaging of the sealing element onto the wall 71 . Said sealing ring 86 is preferably made of a TPE or TPE, while the sealing element 77 is preferably made of a polymer like PE or PP. However, preferably, the sealing element 77 and the sealing ring 86 as a two-components-system is preferably manufactured in a single process step by particular injection moulding. A lower surface of the sealing element 77 is provided with multiple reinforcement ribs 85 to strengthen and stiffen the sealing element to resist relatively high pressures of above 7 bar. The working principle of the device as shown in FIGS. 5 a - 5 c is substantially identical to the working principle of the device 1 shown in FIGS. 1 a - 1 d and elucidated above in a comprehensive manner. [0051] It will be apparent that the invention is not limited to the exemplary embodiments shown and described here, but that numerous variants, which will be obvious to the skilled person in the field, are possible within the scope of the appended claims.
The invention relates to a device for sealing foodstuff containers, in particular drink containers, comprising: a sealing element adapted to engage on a wall of a foodstuff container around a wall opening arranged in the wall, and an operating element adapted to co-act with the sealing element for displacing the sealing element between an opened position leaving the wall opening clear and a closed position sealing the wall opening. The invention also relates to a foodstuff container provided with such a device.
1
TECHNICAL FIELD [0001] This invention relates to the general subject of providing for the flow of fluids in a subsea environment in which volumes are required to be stored under pressure in bottles as a ready reserve and are needed to be deployed to operate low pressure functions, high pressure functions, and functions which require low pressure at one time and high pressure at another time. CROSS-REFERENCE TO RELATED APPLICATIONS [0002] Not applicable. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0003] Not applicable REFERENCE TO A “MICROFICHE APPENDIX” [0004] Not applicable BACKGROUND OF THE INVENTION [0005] The field of this invention is that of providing fluid power to operate subsea components such as the shear rams of subsea blowout preventers and similar components. These components typically make up what is called a subsea blowout preventer stack and have a high volume requirement to operate an appropriate number of these functions. It can range up to 200 gallons of accumulated capacity necessary to operate various blowout preventers and valves on a subsea blowout preventer stack. In many cases such as with shear rams the pressure required to stroke the shear rams to the point of contacting the pipe to be sheared is relatively low (i.e. 500 p.s.i.) and then the force required to shear the pipe is relatively high (i.e. 5000 p.s.i.). [0006] This is further complicated by the fact that an accumulator typically pressurizes the fluid by having compressed gas such as nitrogen provide pressure on the fluid. The compressibility of the gas allows a substantial volume of fluid to be pressurized and then discharged under pressure. A disadvantage of this is that as the liquid is discharged from the accumulator, the volume of the gas becomes larger and therefore the pressure of the gas and liquid becomes lower. As the pistons and rams of the blowout preventer move forward and need higher pressure to do their functions, the pressure of the powering fluid becomes lower. This has typically meant that the lowest pressure from the accumulator must exceed the highest operational pressure of the system. The highest pressure of the accumulator to make this work is simply higher. When a higher pressure is provided by the accumulator than is needed, it is simply throttled to reduce the pressure and turn the energy into heat. [0007] This has been the nature of the operations of subsea accumulators for the past 50 years. There has been a long felt need for more accumulator volume capacity and the only way that those skilled in the art have met the challenge is with larger and higher pressure accumulators. BRIEF SUMMARY OF THE INVENTION [0008] The object of this invention is to provide an accumulator system which provides a relatively lower pressure at the start of the stroke of an operated device and a relatively higher pressure at the end of the stroke of an operated device. [0009] A second object of this invention is to provide a system which fully utilizes the stored energy of an accumulator rather than throttling the pressure and discarding the energy as wasted heat. [0010] A third object of this invention is to provide fluid flow at the pressure which is required by the operated function. BRIEF DESCRIPTION OF THE DRAWINGS [0011] FIG. 1 is a view of a deepwater drilling system such as would use this invention. [0012] FIG. 2 is a partial section of a blowout preventer stack showing conventional operation. [0013] FIG. 3 is a schematic showing the conventional pressure decline of an accumulator as the fluid is discharged. [0014] FIG. 4 is a schematic showing the conventional pressure decline of an accumulator as the fluid is discharged with the area below the graphed line cross hatched to illustrate the energy expended. [0015] FIG. 5 is the schematic of FIG. 3 with an added line indicating the actual pressure requirement of a function to be operated. [0016] FIG. 6 is the schematic of FIG. 5 with the utilized and wasted energy cross hatched. [0017] FIG. 7 is a partial section of a blowout preventer stack showing pumps and motors arranged according to the method of this invention in a simple form. [0018] FIG. 8 is a schematic illustrating how much energy can be saved when operating the function illustrated in FIG. 5 . [0019] FIG. 9 is a schematic illustrating the pressure requirement of a function such as shearing pipe which has a portion of the stroke actually requiring high pressure. [0020] FIG. 10 is the schematic of FIG. 9 with the utilized and wasted energy cross hatched. [0021] FIG. 11 is a schematic illustrating how much energy can be saved by the present method. [0022] FIG. 12 is a partial section of a blowout preventer stack showing pumps and motors arranged according to the method of this invention in variable displacement form. DETAILED DESCRIPTION OF THE INVENTION [0023] Referring now to FIG. 1 , a view of a complete system for drilling subsea wells 20 is shown in order to illustrate the utility of the present invention. The drilling riser 22 is shown with a central pipe 24 , outside fluid lines 26 , and cables or hoses 28 . [0024] Below the drilling riser 22 is a flex joint 30 , lower marine riser package 32 , lower blowout preventer stack 34 and wellhead 36 landed on the seafloor 38 . [0025] Below the wellhead 36 , it can be seen that a hole was drilled for a first casing string 40 , that first casing string 40 was landed and cemented in place, a hole drilled through the first string for a second string, the second string 42 cemented in place, and a hole is being drilled for a third casing string by drill bit 44 on drill string 46 . [0026] The lower Blowout Preventer stack 34 generally comprises a lower hydraulic connector for connecting to the subsea wellhead system 36 , usually 4 or 5 ram style Blowout Preventers, an annular preventer, and an upper mandrel for connection by the connector on the lower marine riser package 32 , which are not individually shown but are well known in the art. [0027] Below outside fluid line 26 is a choke and kill (C&K) connector 50 and a pipe 52 which is generally illustrative of a choke or kill line. Pipe 52 goes down to valves 54 and 56 which provide flow to or from the central bore of the blowout preventer stack as may be appropriate from time to time. Typically a kill line will enter the bore of the Blowout Preventers below the lowest ram and has the general function of pumping heavy fluid to the well to overburden the pressure in the bore or to “kill” the pressure. The general implication of this is that the heavier mud cannot be circulated into the well bore, but rather must be forced into the formations. A choke line will typically enter the well bore above the lowest ram and is generally intended to allow circulation in order to circulate heavier mud into the well to regain pressure control of the well. Normal circulation is down the drill string 46 , through the drill bit 44 . [0028] In normal drilling circulation the mud pumps 60 take drilling mud 62 from tank 64 . The drilling mud will be pumped up a standpipe 66 and down the upper end 68 of the drill string 46 . It will be pumped down the drill string 46 , out the drill bit 44 , and return up the annular area 70 between the outside of the drill string 46 and the bore of the hole being drilled, up the bore of the casing 42 , through the subsea wellhead system 36 , the lower blowout preventer stack 34 , the lower marine riser package 32 , up the drilling riser 22 , out a bell nipple 72 and back into the mud tank 64 . [0029] During situations in which an abnormally high pressure from the formation has entered the well bore, the thin walled central pipe 24 is typically not able to withstand the pressures involved. Rather than making the wall thickness of the relatively large bore drilling riser thick enough to withstand the pressure, the flow is diverted to a choke line or outside fluid line 26 . It is more economic to have a relatively thick wall in a small pipe to withstand the higher pressures than to have the proportionately thick wall in the larger riser pipe. [0030] When higher pressures are to be contained, one of the annular or ram Blowout Preventers are closed around the drill pipe and the flow coming up the annular area around the drill pipe is diverted out through choke valve 54 into the pipe 52 . The flow passes up through C&K connector 50 , up pipe 26 which is attached to the outer diameter of the central pipe 24 , through choking means illustrated at 74 , and back into the mud tanks 64 . [0031] On the opposite side of the drilling riser 22 is shown a cable or hose 28 coming across a sheave 80 from a reel 82 on the vessel 84 . The cable or hose 28 is shown characteristically entering the top of the lower marine riser package. These cables typically carry hydraulic, electrical, multiplex electrical, or fiber optic signals. Typically there are at least two of these systems for redundancy, which are characteristically painted yellow and blue. As the cables or hoses 28 enter the top of the lower marine riser package 32 , they typically enter the top of a control pod to deliver their supply or signals. Hydraulic supply is delivered to a series of accumulators located on the lower marine riser package 32 or the lower Blowout Preventer stack 34 to store hydraulic fluid under pressure until needed. [0032] Referring now to FIG. 2 , a partial section of several parts of the conventional state of the art system for drilling subsea wells is shown including a wellhead connector 100 , ram type blowout preventers 102 and 104 , annular blowout preventer 106 , flex joint 30 , and drilling riser central pipe 24 . [0033] Ram type blowout preventer 104 has pistons 110 and 112 which move rams 114 and 116 into central bore 118 . Fluid flow into line 120 will move the pistons and rams forward to seal off bore 118 with return flow going out line 124 . Fluid flow into line 124 will move the pistons and rams out off bore 118 with return flow going out line 120 . [0034] Control pod 130 receives electric and communication signals from the surface along line 132 and receives hydraulic supply from line 134 , and exhausts hydraulic fluid to sea along line 136 . Accumulator 140 receives pressurized hydraulic supply from the surface along line 142 and supplies the control pod 130 when appropriate. Electro-hydraulic valve 138 receives hydraulic supply from accumulator 140 and directs the hydraulic supply to open or close the rams of blowout preventer 104 [0035] Referring now to FIG. 3 , a graph is shown for fluid which might be coming out of an accumulator such as is shown at 140 . For understanding, this graph presumes that the accumulator will go from fully charged to fully discharged when moving one function from open (fully charged) to closed (discharged) as shown by line AB. In reality an accumulator might operate several functions, or several accumulators can be required to operate one function. [0036] Referring now to FIG. 4 , the area under line AB is cross hatched. As the energy expended from an accumulator is proportionate to the product of the volume times the pressure, the cross hatched area is generally an indication of the amount of energy of the accumulator. [0037] Referring now to FIG. 5 , line CD indicates the actual flow and pressure which could be utilized to close a function. It generally indicates that 900 p.s.i. will close it, but the entire volume of the accumulator is required. [0038] Referring now to FIG. 6 , the area below line CD is proportionate to the utilized energy in closing the function and the cross hatched area between lines AB and CD is wasted energy. This energy in excess of the required amount will be burned up in faster than required operations and resultant line flow friction losses. This generally indicates that 25% of the energy was used and 75% of the energy was wasted. [0039] Referring now to FIG. 7 , the output of accumulator is not directed to control valve but rather to motor 150 . Motor 150 output torque is directed to drive pumps 152 , 154 , and 156 , all of which have the same volume displacement for the purpose of this example. As line 134 required 900 p.s.i. in the example of FIGS. 5 and 6 , line 158 will require 3*900=2700 p.s.i. to drive the motors, which is readily available from the accumulator 140 . Low pressure tank 160 is provided to collect the returns from control valve 138 such that when 3 times as much is drawn from tank 160 by pumps 152 , 154 , and 156 as is put into tank by motor 150 , standard control fluid will be available. As control valve 138 exhausts into tank 160 , excess flow will be vented to sea through line 162 . [0040] Referring now to FIG. 8 , this is shown graphically. On the X scale is can be seen that only ⅓ of the volume of the accumulator was expended, and the Y scale shows that it was expended at 3 times the pressure, for the same cross hatched area below line EF. The wasted energy between lines EF and GH is less than ¼ of the wasted energy as seen in FIG. 6 to do the same job. Referring now to FIG. 9 , line JKLMNP indicates a special operation such as a shear ram on a subsea blowout preventer stack in which a higher pressure is actually needed. In this case as the pistons moved from J to K, the same 900 p.s.i. was required as was in the prior figures. When the shearing of the steel pipe was being done, 2900 p.s.i. as shown in line segment LM was required. After the shearing was accomplished, only 900 p.s.i. was required to continue moving to the sealing position as shown line segment NP. [0041] Referring now to FIG. 10 , it can be seen that the wasted energy between lines JKLMNP and AB is almost as much as was wasted in FIG. 6 . [0042] Referring now to FIG. 11 , if all the accumulator pressure is expended at the maximum required pressure, we can reduce the required volume by more than 50 percent and substantially reduce the wasted volume as is seen between lines AQ and RS. [0043] Referring now to FIG. 12 , the three pumps 152 , 154 , and 156 of FIG. 7 are replaced by a single pump 170 . The pump 170 is a variable displacement pump which is horsepower limited. This means that when the combination of pressure and flow rate (a measure of horsepower) exceeds a maximum, the variable flow rate is lowered until the horsepower setting is not exceeded. In the example of FIGS. 9 and 10 , if the horsepower is set to that calculated by the given flow rate times 2900 p.s.i., the pipe will be sheared as was anticipated in FIGS. 9 and 10 . At the times when the pipe is not being sheared, the 2900 p.s.i. cannot be achieved in line 134 . As a result the variable displacement pump will change the displacement until the increased flow times 900 p.s.i. will equal the original flow time 2900 p.s.i. In this case the flow will need to be adjusted upwardly by (2900/900=3.22) a factor of 3.22/1. As the same volume is actually required to move the pistons and rams, it means that in the non-shearing portion of the stroke, the volume required from the accumulator will be reduced by a factor of 3.22. [0044] Referring back to FIG. 11 , it can be seen that the net required volume from the accumulators can be reduced by more than 50%. This means that the size of the required accumulators can be reduced to accomplish the set of required tasks, or that more capability can be provided by the same accumulators. [0045] The same benefit can be obtained if the motor is the variable displacement device and the pumps are fixed displacement. The volume output of the pumps is generally inversely proportionate to the required pressure to operate the device to be operated. [0046] The previous examples have shown how to increase the flow volume from an accumulator to an operated device. Alternately, the flow to the device can be decreased in order to achieve a higher pressure. [0047] 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. Accordingly, the protection sought herein is as set forth in the claims below. [0000] SEQUENCE LISTING: N/A
In a subsea system where subsea devices are operated using a pressurized fluid from one or more accumulators, the method of providing flow of pressurized fluid to operate a device which is greater than the flow from an accumulator providing the flow, comprising discharging the accumulator to drive one or more motors, driving one or more pumps by the one or more motors, the one or more pumps having a larger displacement than the one or more motors such that the one or more pump outputs a greater volume of fluid than the motor consumes, and delivering the output of the one or more pumps to operated the subsea device.
4
BACKGROUND [0001] In the rearing of animals, such as companion animals and livestock, ectoparasites cause enormous losses, including economic losses, particularly because many ectoparasites can act as disease vectors. [0002] The control of animal ectoparasites is an ongoing challenge. For example, numerous strains of ticks have developed resistance to a wide range of pesticides such as arsenic, hexachlorohexane, camphechlor, DDT, pyrethrines, carbamates and organophosphorous compounds despite the fact that these compounds have varied modes of action and several distinct primary sites of attack in the ectoparasite. It is therefore generally accepted that it is highly desirable to develop and commercialize additional active agents with new modes of action for ectoparasite control. [0003] Compounds harboring a quinazole, pyrazole or pyrimidine core are well known for their fungicidal, insecticidal and miticidal use in the crop chemistry applications (e.g., U.S. Pat. No. 5,411,963). However several reports have indicated that fenazaquin and tebufenpyrad have limited spectrum of activity against insect pests as well as relatively low toxicity to beneficial mite species under normal use ( Pest Manag Sci 2005 61(2):103-10). SUMMARY [0004] Described herein are methods for preventing and/or repressing ectoparasites of animals. The methods include the application to the animal of an effective amount of a composition that includes: 4-tert-butylphenethyl quinazolin-4-yl ether (fenazaquin), 4chloro-5-ethyl-2-methyl-N-[(4-tert-butylphenyl)methyl]pyrazole-3-carboxamide (tebufenpyrad), 5-chloro-N-[2-[4-(2-ethoxethyl)-2,3-dimethylphenoxy]ethyl]-6-ethyl-4-pyrimidinamine (pyrimidifen). Fenazaquin, tebufenpyrad and pyrimidifen are thought to affect metabolism by inhibiting the mitochondrial electron transport chain by binding with Complex I at co-enzyme Q 0 and represent a novel mode of action for ectoparasite control in animal health. [0005] The unexpected anti-tick and anti-flea properties of certain mitochondrial electron transport inhibitors are of considerable significance since there are relatively few agriculture pesticides that can be effectively be used against ectoparasites of animals. [0006] Compositions and processes for controlling ectoparasites of animals are described herein. The methods entail the use of compositions that include: 4tert-butylphenethyl quinazolin-4-yl ether (Formula I), 4-chloro-5-ethyl-2-methyl-N-[(4-tert-butylphenyl)methyl]pyrazole-3carboxamide (Formula II), 5-chloro-N-[2-[4-(2-ethoxyethyl)-2,3-dimethylphenoxy]ethyl]-6-ethyl-4-pyrimidinamine disclosed as formula III, to control ticks, mites, fleas, flies, and lice that infest animals. [0000] [0007] The compounds in Formula I, Formula II and Formula III are suitable for controlling arthropods which attack agricultural livestock such as, for example, cattle sheep, goats, horses, pigs, donkeys, camels, buffaloes, rabbits, chickens, turkeys, ducks, geese, other domestic animals such as, for example, dogs, cats, caged birds, aquarium fish and so-called experimental animals such as, for example, hamsters, guinea pigs, rats, and mice. By controlling these anthropods, cases of death and reductions in productivity (for meat, milk, wool, hides, eggs, and the like) can be lessened, so that more economical and simpler animal husbandry is possible. [0008] The details of one or more embodiments of the invention are set forth in the accompanying description below. Other features, objects, and advantages of the invention will be apparent from the description and from the claims. DETAILED DESCRIPTION [0009] Several compounds having activity as mitochondrial complex 1 inhibitors were commercialized in the 1990s for the purpose of protecting crops and other plants from predation by plant pests such as spider mites (e.g., two spotted spider mite) or rust mites (e.g., apple rust mite). These compounds include fenazaquin (4-tert-butylphenyl quinazolin-4-yl ether), tebufenpyrad (4-chloro-5-ethyl-2-methyl-N-[(4-tert-butylphenethyl)methyl]pyrazole-3-carboxamide), pyrimidifen (5-chloro-N-[2-[4-(2-ethoxyethyl)-2,3-dimethylphenoxy]ethyl]-6-ethyl-4-pyrimidinamine), fenpyroximate (tert-butyl 4-[[(1,3-dimethyl-5-phenoxy-pyrazol-4-yl)methylideneamino]oxymethyl]benzoate), pyridaben (4-chloro-2-tert-butyl-5-[(4-tert-butylphenyl)methylsulfanyl]pyridazin-3-one) and tolfenpyrad (4-chloro-3-ethyl-1-methyl-N-[4-(p-tolyloxy)benzyl]pyrazole-5-carboximide). [0000] [0010] Despite acting at a conserved site (coenzyme Q 0 of Complex I) and interfering with an essential process (mitochondrial electron transport) these pesticides nonetheless show surprising and unpredictable species selectivity. Although used primarily as acaricides against plant parasitic mites, fenazaquin, fempyroximate, pyridaben and tebufenpyrad have minimal impact on predatory mites and many beneficial insects under field conditions ( Pest Manag Sci 2005 61(2):103-10). [0011] A specific example of the large spades dependent differences in potency of complex I inhibitors is seen for fenazaquin in a study by Hackler et al. Fenazaquin is highly active against cotton aphids (LC 50 of 2.6 ppm) and against mosquito larvae of (LC 50 of 0725 ppm) but has low potency against the against cabbage looper (LC 50 188 ppm) and greater than 400 ppm activity against both southern corn rootworm and tobacco budworm (Hackler et al. 1998 Development of broad-spectrum insecticide activity from a miticide. In: Synthesis and Chemistry of Agrochemicals V (Bakeret al.; eds), American Chemical Society, Washington D.C., pp. 147-150). These species sensitivity differences could be due to intrinsic activity differences (i.e., active site changes), metabolism differences and/or penetration differences. For example, fenazaquin is extensively metabolized by the tobacco bud worm, which may explain the poor efficacy against this species. Additionally fenazaquin is degraded more extensively by rat liver microsomes than by trout liver microsomes which may partially explain the higher toxicity of the compound to fish than to mammals. At present, these species-dependent differences in the interactions of the compounds with the active sites, or metabolism or penetration differences are impossible to predict a priori. [0012] Surprisingly we have found that fenazquin (4-tert-butylphenethyl quinazolin-4-yl ether) and contain other mitochondrial complex I inhibitors are active on fleas and ticks, two distantly related groups of arthropods that are both commercially important ectoparasites in animal husbandry. [0013] The compounds 4-tert-butylphenethyl quinazolin-4-yl ether, 4-chloro-5-ethyl-2-methyl-N-[(4-tert-butylphenyl)methyl]pyrazole-3-carboxamide, and 5-chloro-N-[2- [4-(2-ethoxyethyl)-2,3-dimethylphenoxy]ethyl]-6-ethyl-4-pyrimidinamine, are contemplated to be active against animal parasites (ectoparasites) such as hard ticks, soft ticks, mange mites, harvest mites, lice, hair lice, bird lice and fleas. These parasites include the ectoparasites of the order Acari of the family Ixodidae, e.g., the cattle ticks such as Boophilus spp e.g. Boophilus microplus, Boophilus decoloratus and Boophilus annulatus; Rhipicephalus spp such as Rhipicephalus sanguineus, Rhipicephalus appendiculatus, Rhipicephalus pulchellus and Rhipicephalus evertsi; Hyalomma spp such as Hyalomma truncatum, Hyalomma rufipes, Hyalomma detritum, Hyalomma marginatum, Hyalomma dromedaril and Hyalomma anatolicum excavatum; Dermacentor species such as Dermacentor variabilis and Dermacentor andersoni; Amblyomma spp such as Amblyomma variegatum, Amblyomma herbraeum, Amblyomma pomposum, Amblyomma americanum, Amblyomma cayennenese, Amblyomma maculatum, Amblyomma gemma and Amblyomma lepidhon; of the family Argasidae, e.g., Otobius spp such as Otobius megnini and Ornithodores spp such as Ornithodoros savignyi, Ornithodoros lahorensis and Ornithodoros tholozani; of the family Psoroptidae, e.g., Psoroptes ovis and Psoroptes equi; and of the family Sarcopidae e.g. Sarcoptes bovis or Sarcoptes scabici; ectoprasites of the order Diptera, which includes biting and sucking flies; ectoparasites of the order Phthiraptera, which includes sucking and chewing lice; and ectoparasites of the order Siphonaptera, including but not limited to the cat flea ( Ctenocephalides felis ) and the dog flea ( Ctenocephalides canis ). [0014] The active compounds can be enterally administered in the form of, for example, tablets, capsules, potions, drenches, granules, pastes, boluses, the feed-through method, suppositories. The compounds can be parenterally administered such as, for example, by injections (intramuscularly, subcutaneously, intravenously, intraperitoneally and the like). The compounds can also be administered as implants, by nasal administration, by dermal administration in the form of, for example, immersing or dipping, spraying, pouring-on, spotting-on, washing, dusting, and with the aid of active-compound-comprising molded articles such as collars, ear tags, tail tags, limb bands, halters, marking devices and the like. [0015] The active compound content of the use forms prepared from the commercially available formulations can vary within wide limits. The active compound concentration of the use forms can be from 0.0000001 to 95% by weight of active compound, preferably between 0.0001 and 10% by weight. [0016] When used for cattle, poultry, domestic animals and the like, the active compound combinations can be applied as formulations (for example powders, emulsions, flowables) comprising the active compounds in an amount of 1 to 80% by weight, either directly or after 100- to 10,000-fold dilution or they may be used as a chemical dip. [0017] The compound of formula I, II and III are applied to the ectoparasites of the order Acari, in free base form or in agriculturally acceptable acid addition salt form, e.g., as hydrochloride or acetate, by topical treatment of the animals, e.g., by dusting, by dipping or by spray treatments with dilute aqueous form. The compound of formula I, II and III are preferably used in free base form. The degree of dilution may vary although preferably a concentration in the range of 0.01 to 5.0%, particularly of 0.02 to 0.1%, by weight of the active agent is employed. The treatment is preferably repeated at intervals of between 7 to 21 days. [0018] The active agent can be conveniently formulated as a dust, dust concentrate, wettable powder, emulsifiable concentrate or as a solution, with conventional solid or liquid adjuvants. Particularly preferred compositions of the invention are liquid concentrates, especially those containing preferably 3.0 to 50% by weight of active agent, to be diluted with water before use. Such liquid concentrate preferably includes an emulsifying agent such as a polyglycolether derived from a high molecular weight alcohol, mercaptan or alkyl phenol with an alkylene oxide as well as a diluent such as a liquid aromatic hydrocarbon or mineral oil. [0019] Suitable solid carriers are for example ammonium salts and ground natural minerals such as kaolins, clays, talc, chalk, quartz, attapulgite, montmorillonite or diatomaceous earth, and ground synthetic materials such as highly-disperse silica, alumina and silicates; suitable solid carriers for granules are: for example crushed and fractioned natural rocks such as calcite, marble, pumice, sepiolite and dolomite, or else synthetic granules of inorganic and organic meals, and granules of organic material such as sawdust, coconut shells, maize cobs and tobacco stalks; suitable emulsifiers and/or foam formers are: for example nonionic and anionic emulsifiers such as polyoxyethylene fatty acid esters, polyoxyethylene fatty alcohol ethers, for example alkylaryl polyglycol ethers, alkylsulphonates, alkyl sulphates, arylsulphonates, or else protein hydrolysates; suitable dispersants are: for example lignin-sulphite waste liquors and methylcellulose. [0020] Carboxymethylcellulose and natural and synthetic polymers in the form of powders, granules or latices, such as gum arabic, polyvinyl alcohol and polyvinyl acetate, or else natural phosopholipids such us cephalins and lecithins and synthetic phospholipids can be used in the formulations, Other additives can be mineral and vegetable oils. It is possible to use colorants such inorganic pigments, for example iron oxide, titanium oxide and Prussian Blue, and organic colorants such alizarin colorants, azo colorants and metal phthalocyanine colorants, and trace nutrients such as salts of iron, manganese, boron, copper, cobalt, molybdenum and zine. [0021] The formulations generally comprise between 0.1 and 95% by weight of active compound, preferably between 0.5 and 90%. [0022] The action of the compounds in Formula I, II and III against animal ectoparasites can be seen from the examples which follow. The examples are to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any whatsoever. All of the publications cited herein are hereby incorporated by reference in their entirety. EXAMPLE 1 Activity Against A. Americanum Larvae in a Dip Survival Assay [0023] Compound 1 from a dimethyl sulfoxide (DMSO) stock or 2% DMSO alone is dispensed into a round-bottom 96-well plate and mixed with aqueous buffer containing 1% ethanol, 0.2% Triton X100. The final DMSO concentration does not exceed 2%. Larval-stage lone star ticks ( Amblyomma americanum ) are dispensed into the wells containing the Compound and submerged for 30 minutes. The ticks are subsequently dispensed into a tissue biopsy bag, which is allowed to dry for 1 hour. After drying, the bags are incubated at 25° with 95% humidity for 24 hours and the number of live or dead larvae are enumerated. The observations made illustrated in the following table. [0000] 0.05% 0.01% 2% DMSO Formula I Formula I Number of 43/2 0/48 0/52 live/dead A. americanum larvae 24 hours after treatment
Disclosed is a method of controlling ectoparasites that infest companion and livestock animals by applying to the animal an effective amount of 4 -tert-butylphenethyl quinazolin- 4 -yl either or 4 -chloro- 5 -ethyl- 2 -methyl-N-[( 4 -tert-butylphenyl)methyl]pyrazole- 3 -carboxamide or 5 -chloro-N-[ 2 -[ 4 ( 2 -ethoxyethyl)- 2,3 -dimethylphenoxy]ethyl]- 6 -ethyl- 4 -pyrimidinamine.
0
BACKGROUND [0001] 1. Field of the Invention [0002] The subject invention relates to the field of internet security and, more specifically, to validation of users accessing website. [0003] 2. Related Art [0004] Providers of on-line information or services on the Internet often want or need to restrict access to the information or services offered on their websites. In many cases, simply allowing access to humans and not to a machine, e.g., a robot or crawler, provides some level of security against abuse for spam and other nefarious purposes. The method used today to ensure that the accessing party is human is called CAPTCHA (Completely Automated Public Turing Test to Tell Computers and Humans Apart) or Human Interactive Proofs. The idea behind CAPTCHAs is that there are tasks that humans are better at than computers. By providing a test easy for humans to solve but hard for computers, the service providers can increase the likelihood that their users are humans. The security bar is fairly low in that designers of CAPTCHAs only need to create CAPTCHAs that are sufficiently hard that it would be more economical to entice people to solve the CAPTCHAs than to create programs to solve them. [0005] The commercially used CAPTCHAs often use a string of letters and digits randomly generated and morphed so they would be harder for optical character recognition (OCR) or other pattern recognition algorithms to recognize. However, there are also limitations to how much the letters can be distorted and yet be recognizable to humans. One often cited threshold is that humans' success rate should be 90%, while computers' should only be 0.01%. Even with a human success rate of 90%, the users will fail one out of ten trials which causes frustration towards the service provider. In addition, due to large individual variations in the human perceptual system, the distorted letters can be hard to read for many people and lead to exclusion of these users. For this reason it is highly desirably to create CAPTCHAs that are as easy as possible to solve by humans yet preserve or increase the difficulty for computers to solve them. [0006] Some CAPTCHA designs, like logic puzzles or “which shape does not belong,” have the feel of intelligence tests. For many service providers it is not advisable to question their users' intelligence, especially when they want to have as many users as possible. Instead CAPTCHAs should be almost trivial for a person to solve. [0007] All aspects of a service provider's webpages affect a user's impression of the company. CAPTCHAs are often prominent on corporate pages. For this reason, the aesthetics of the CAPTCHAs are important. Currently the aesthetical aspects of the CAPTCHAs are overlooked in comparison to the security aspects. In addition, previous research has shown that users' perception of beauty influences their perception of the ease of use. The majority of CAPTCHAs use degraded text, images, or audio, which not only make the CAPTCHAs less easy for humans, but also make them less attractive. [0008] Therefore, there is a need in the art for improved CAPTCHAs that are easy for human, but very difficult for a machine to solve, yet appear aesthetically pleasing. SUMMARY [0009] Various embodiments of the invention provide improved CAPTCHAs that form primarily a perceptual task, are easily resolved by human visual perception, and are difficult for machines to resolve. [0010] According to aspects of the invention, various CAPTCHAs are generated that can be easily resolved by human sense of motion. [0011] According to other aspects of the invention, CAPTCHAs are generated that are aesthetically pleasing. Such CAPTCHAs are not based on degrading images, but on obscuring images in a way that is both attractive and easily perceived by humans while not by machines. [0012] According to an aspect of the invention, an automated test to tell computers and humans apart is disclosed, which comprises: displaying on a computer screen an animation comprising of at least a first layer and a second layer, one of the first layer and second layer comprising a plurality of recognizable images and the other comprising partial obstruction of the recognizable images, and wherein the animation comprises relative motion between the first and second layer. The animation may include two or more layers, each layer may be stationary or movable. The motion of each movable layer can be made automatic, as in an animation loop, or in response to a user input, such as by “grab and drag.” [0013] According to an aspect of the invention, an automated test to tell computers and humans apart is disclosed, comprising displaying on a computer screen an animation comprising of a foreground and a background, one of the foreground comprising a plurality of typographical characters and the other comprising partial obstruction of the typographical characters, and wherein the animation comprises relative motion between the background and foreground. The typographical characters may be provided in an incomplete form. The animation may be played automatically or in response to a user input. The method may further include monitoring keyboard or other user input device activity as the animation is presented. [0014] According to another aspect of the invention, an automated test to tell computers and humans apart is provided, comprising displaying on a computer screen an image, and requiring the user to perform operation on the image to resolve an encoded solution. The operation may comprise moving part of the image using a user input device. According to another aspect, the operation may comprise matching part of the image with another part of the image, or matching part of the image with another part of another image. According to a further aspect, the operation may comprise matching typographical characters presented in a first set with typographical characters presented in a second set. The attributes of characters presented in the first set may be different from attributes of corresponding characters presented in the second set. The attributes may comprise at least one of capital case, lower case, size, bold, font, color, shading and italic. Each of the characters may be presented in an incomplete form. According to an aspect of the invention, the matching comprises using a user input device to move each character from the first set into a position overlapping a corresponding character of the second set. [0015] According to yet another aspect of the invention, an automated test to tell computers and humans apart is provided, comprising displaying on a computer screen a video clip, and requiring a user to provide an input corresponding to subject matter presented in the video clip. The user may be required to provide an input when the subject matter presented in the video clip has changed. The user may be required to type typographical characters corresponding to typographical characters presented in the video clip. The user may be required to solve the test by typing the subject matter of the video clip. The user may be provided with a second video clip and be required to solve the second test by typing a second subject matter corresponding to the second video clip and, if the user properly solves the test, storing the user's solution of the second test to compare to other users' solutions of the second test. Then, when a statistically significant number of solutions to the second test have been received, the method proceeds by determining whether the second test is valid and, if so, selecting a solution most commonly entered for the second test as being a proper solution. [0016] Other aspects and features of the invention will become apparent from the description of various embodiments described herein, and which come within the scope and spirit of the invention as claimed in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS [0017] The invention is described herein with reference to particular embodiments thereof, which are exemplified in the drawings. It should be understood, however, that the various embodiments depicted in the drawings are only exemplary and may not limit the invention as defined in the appended claims. Furthermore, because various embodiments of CAPTCHAs described herein involve motion, the static drawings cannot fully depict every element of these CAPTCHAs, but nevertheless, the artisan can fully understand the construct from the static drawings when viewed in conjunction with the relevant disclosure. [0018] FIG. 1 depicts a CAPTCHA according to the prior art. [0019] FIGS. 2 a and 2 b illustrate an animated CAPTCHA generated according to an embodiment of the invention. [0020] FIGS. 3 a and 3 b depict another example of a motion-based CAPTCHA. [0021] FIG. 3 c illustrate the embodiment of FIGS. 3 a and 3 b , modified so that parts of the characters are missing throughout the complete animation. [0022] FIGS. 4 a and 4 b depict an interactive CAPTCHA according to an embodiment of the invention. [0023] FIG. 5 depicts another interactive CAPTCHA according to an embodiment of the invention. [0024] FIG. 6 depicts an example of a multi-layer CHAPTCHA according to an embodiment of the invention. [0025] FIGS. 7 a and 7 b depict an example of a video CAPTCHA according to an embodiment of the invention. [0026] FIGS. 8 a and 8 b depict an example of a video CAPTCHA employing random elements feature. [0027] FIG. 9 depicts an example of a multiple layer embodiment. [0028] FIG. 10 depicts another example of an embodiment having multiple layers. DETAILED DESCRIPTION [0029] Various embodiment of the present invention enable designing CAPTCHAs that require primarily a perceptual task to resolve. Such CAPTCHAs require a task that could be performed without the intelligence associated with human beings, but rather by using human's perception of motion and ability to process visual cues. [0030] Human perception and visual processing is tuned to perceive and make sense of motion. One example of this is the old invention of tachyscope. A tachyscope makes still images come alive by attaching them to a cylindrical board and spinning the board, while keeping the eyes on a specific location of the board. Similarly, when driving past a fence with vertical openings between the boards, the view of the scenery on the other side of the fence appears uninterrupted until the car is stopped. In psychology, this effect is referred to as anorthoscopic perception. These examples show how human visual systems excel at integrating low resolution or conflicting images into apparently high resolution and complete images over time. This phenomenon is utilized in various embodiments of the invention. [0031] FIG. 1 depicts a CAPTCHA according to the prior art. As can be seen, the CAPTCHA is basically the four letters “SMWM” depicted in a distorted form. The distortion makes it difficult for OCR algorithm, but is rather simple for humans to decipher. However, various algorithms have been developed that gain some success in resolving such CAPTCHA. On the other hand, FIGS. 2 a and 2 b illustrate an animated CAPTCHA generated according to an embodiment of the invention, wherein a foreground layer partially obstruct the solution. The task in the example of FIGS. 2 a and 2 b is also to decipher the letters presented, in this example “ABCD.” However, in this embodiment the letters are not distorted. Rather, the CAPTCHA is in the form of a looped animation, wherein the foreground always obstruct part of the solution. That is, motion is imparted either to the letters, to the foreground, or to both. In the example illustrated in FIGS. 2 a and 2 b , the letters are moving upwards, while the foreground is moving from right to left. That is, FIGS. 2 a and 2 b are “snap shots” of the CAPTCHA animation at two different points in times. As can be understood, when the complete animation is presented to a user in a continuous manner, the user will be able to easily decipher the letters, as at each point in time the user will see part of the solution and will be able to easily integrate the parts to decipher the whole. On the other hand, an OCR algorithm would not be able to decode this CAPTCHA, since the letters are never shown in a complete form. Also, as can be seen from FIGS. 2 a and 2 b , such a CAPTCHA is more aesthetically pleasing, as it almost appears as a game. [0032] As can be understood, while the example of FIGS. 2 a and 2 b show moving bubbles as a foreground, other foregrounds can be used, so long as at each point in time only parts of the letters are shown, while other parts are covered. To illustrate, FIGS. 3 a and 3 b depict another example of a motion-based CAPTCHA. In this example, the letters “ABCD” are stationary, but the vertical black lines move from right to left. As can be understood, part of a vertical line will always cover a part of each letter. Therefore, none of the letters is ever shown completely exposed. However, when the lines are moving, human can perceive the letters easily. In the depicted example, the letters and moving foreground are shown in black and white. However, for a more pleasing experience, the letters and foreground can be provided in any desired color. Still, for best secure results, the foreground and letters should be of the same color. Also, while the examples here are given in terms of letters, any typographical character can be used, e.g., numbers, shapes, symbols, etc. Therefore, in this specification we refer to the term “encoded solution” as encompassing any of the characters that may be used in the CAPTCHA, such as letters, numbers, etc. Furthermore, as will be discussed below, the solution need not necessarily be a typographical character, but can be any recognizable image, which also comes under the term “encoded solution.” [0033] As can be understood, the animated CAPTCHA are similar to the prior art CAPTCHAs in that both use characters as the encoded solution. However, prior art CAPTCHA's are of a single-frame, while inventive animated CAPTCHAs use multiple frames. The motion created by playing the frames makes the message perceptually pop out and it becomes easy to decode for humans. However, since the inventive animated CAPTCHAs provide more frames that can be machine-processed to solve the problem, more data is available for automatically breaking the animated CAPTCHA. Accordingly, when generating the animated CHAPTCHA, it is advisable to follow the following guidelines: The set of characters may be a larger class than letters. As noted above, other symbols can be used; however, the symbols need to be well known for the group of users. A possible class of symbols could consist of easily recognizable items, for example, animals or fruits and vegetables. Depending on the level of security that is needed for the system, letters and digits might be a good enough choice. Variations can include, Arabic numerals, Roman numerals, shapes, typographical characters, such as #, &, @, etc. While the encoded solution or the background alone can be moving, for best results both the foreground/background and the encoded solution should be moving. In addition, distracting elements could be moving in the same direction as the encoded solution. This makes time averaging over the frames and tracking of the message harder. Also, while the examples are given in terms of foreground and background, multiple layers can be used, wherein each layer may be moving or stationary. The motion of each layer may be independent of the motion of any other layer. Furthermore, the motion can be automatic, i.e., a continuous loop, or manual in response to a user's command. A manual motion can be, for example, the clip plays a number of frames in response to a user's mouse click, or motion is made in response to user's “dragging” of selected layer using a mouse or other input device, or a specific motion that depends on the user's action, e.g., foreground moves to left upon left-mouse click and to the right upon right-mouse click. The portions of the encoded solution that are visible should be changing over time. In addition, the sum of all frames can be set as not to give a complete image of the encoded solution. As is known, human perception is very good at “completing the picture” even when elements are missing. This is exemplified by the embodiment shown in FIG. 3 c , which is generally the embodiment of FIGS. 3 a and 3 b , modified so that parts of the characters are missing throughout the complete animation. That is, the parts are missing even if all of the frames are put together. In this example, the parts are deleted by running two blocking lines 300 across the image; however, other method can be used. To generalize, the embodiment of FIG. 3 c is generated by presenting the typographical characters in an incomplete form. That is, part of each letter is always missing. The color of the message and the background/foreground should be matched so that the symbols cannot be trivially detected. If several colors are used, the colors should be chosen so that when converting the image to black and white, the colors would be in the same gray nuance. If several layers are used, each of different color, their overlap can be set to provide the same gray nuance as the solution. [0038] According to another aspect of the invention, interactive CAPTCHA are generated, which are easily solved by a human, but difficult for a machine to solve. Interactive CAPTCHA requires the user to perform some actions to view or construct a hidden message. The actions can either be mouse input or keyboard input (for example arrow keys). An interactive CAPTCHA can, for example, ask the user to move the background/foreground to get a different view of the message. This example is illustrated in FIGS. 4 a and 4 b . FIG. 4 a depicts the first frame of the interactive CAPTCHA. As can be seen, the foreground exposes only part of the encoded solution. In order to view the rest of the encoded solution, the user must take an action, such as move the foreground in the direction of the arrow, so as to expose the other parts of the message as shown in FIG. 4 b . Of course, rather than moving the foreground, the user may also be asked to move the encoded solution itself, so that the remainder appears through the openings in the foreground. [0039] As can be understood, the embodiment of FIGS. 4 a and 4 b can be implemented using animation CAPTCHA as well. That is, the embodiment of FIGS. 4 a and 4 b can be implemented as an animation clip that requires the user's input in order to play the sequence. For example, the animation can be generated to move the foreground from left to right, as is shown by the arrow; however, the animation is not set in motion until the user takes an action, such as click the mouse or press “enter” on the keyboard. In this sense, the embodiment of FIGS. 2 a and 2 b can be thought of as automatic animation CAPTCHA, while that of FIGS. 4 a and 4 b a manual CAPTCHA. Conversely, the embodiments of FIGS. 2 a , 2 b , and 3 a - 3 c can be made as an interactive CAPTCHAs, i.e., the user must take an action to cause a motion, such as dragging a layer or clicking to set the clip in motion or to play part of the clip. [0040] Another example is that the CAPTCHA asks the user to perform a matching task. Such an example is illustrated in FIG. 5 . The Example of the interactive CAPTCHA of FIG. 5 asks the user to match the letters in the top field with the letters in the bottom field. The matching can be done, e.g., by selecting and dragging a letter from the top field and placing it on top of its counterpart in the bottom field, or vice versa. As shown in the example of FIG. 5 , the task is made more difficult for a machine to resolve by interchanging the characters attributes, e.g., Capital and Lower-Case letters on the top and bottom field. Other changes can include the use of different font, different attributes, such as size, bold, italic, color, shading, etc. In this manner, the matching is not only of a shape, but requires knowledge of the alphabet and its printable and usage variations. As is also exemplified in FIG. 5 , none of the typographical characters is depicted in a complete form. Part of each typographical character is missing. This can be easily overcome by humans, but may present a challenge to a computer to resolve. [0041] According to another embodiment, in addition to the user's solution to the CAPTCHA, the user's actions (keyboard or mouse input) can be tracked using conventional means. Based on this information, the CAPTCHA can determine if the actions correspond to natural human behavior or if they could be computer generated. [0042] According to yet another embodiment, video-based CAPTCHAs are generated. The video-based CAPTCHAS ask a user to provide a response based on what is presented in a video clip. Possible questions could be, for example: What activity is being performed in the video clip? For enhanced security, the activity should not be deducible from a single frame or pair of frames. When does a person change activities in the video clip? Is this real life or science fiction video clip? Is this object moving forward, backwards, or staying still? There could be camera motion, object motion, or both. Is the segment running forward, backwards, or in fast forward mode? What emotion are the people in the segment displaying? [0049] FIG. 6 depicts an example of a multi-layer CAPTACH wherein the solution is divided and distributed among various layers, in this example, two layers 603 and 605 . In this example there is also a background layer 601 and an obstruction foreground layer 607 . Any of the layers can be moving under any of the methods described above, e.g., closed loop animation, user interaction, etc. The idea here is that in addition to the foreground layer partially obstructing the solution, the layers comprising the solution must also be aligned in order to decipher the solution. In this example, when layers 603 and 605 are aligned, the partial solutions encircled by ovals 602 and 604 form the completed solution “E”, while the partial solutions encircled by ovals 606 and 608 form the complete solution “A.” That is, each layer includes a partial solution that is complementary to a partial solution included in another layer or layers (i.e., the solution can be distributed among more than two layers). [0050] FIGS. 7 a and 7 b depict an example of a video CHAPTCHA according to an embodiment of the invention. As is shown in FIG. 7 a , a video clip 710 is played, depicting a person running from left to the right side of the screen 700 . A timeline 720 is presented in the form of a bar having empty rectangles therein, which are being filled progressively from left to right as time passes, i.e., as the playing of the video clip progresses. A caption, 730 , asks the user to perform a task that relies on information conveyed in the video clip. In this example, the user is requested to click on the timeline when the activity on the screen changes. As shown in FIG. 7 b , when the fourth time rectangle has been filled, the person ceased running and is shown seated on a chair. At this time, if the user clicks on the timeline, it is interpreted as a correct solution to the CAPTCHA. On the other hand, the user may be allowed to click at any time, as long as the user clicks at the proper location on the time bar, in this example, the fourth filled time rectangle. This allows the user to provide a delayed response. [0051] According to yet another embodiment, an element is added to the video, such as a message (or question, or object, etc.) that changes over time. The user is then asked to type the message (or answer the question, or identify the object) that is displayed at the time the user notices a specific semantic feature in the video. The additional element need not be obscured since the main challenge is identifying semantic video features. An example of a video CAPTCHA employing the added elements feature is shown in FIGS. 8 a and 8 b . FIGS. 8 a and 8 b depict an embodiment wherein the element that is shown in the screen is random, and the user is asked to type the element that is shown at the time the subject matter of the video changes. In the example of FIGS. 8 a and 8 b , the video clip shows a person running (e.g., FIG. 8 a ) and various random words are flashing on the screen, e.g., “cat” in FIG. 8 a . When the subject matter of the video changes, e.g., the person in the video is seated in FIG. 8 b , the user is asked to type the random word that appeared at the time, here the word “dog.” [0052] One problem with CAPTCHAs, particularly those based on images, video, or interaction, is that it can be hard to anticipate reasonable human responses. Part of the reason that the most deployed CAPTCHAs are letter based is that the correct response is unambiguous. The desire for an unambiguous label for each CAPTCHA severely limits the design space and opens the possibility to easier break the CAPTCHA. According to an embodiment of the invention, users are required to solve multiple CAPTCHAs consisting of two sets, one already vetted CAPTCHAs and a set of novel CAPTCHAs. A user does not know which is which and is required to attempt all elements of both sets. The answers to the first set determine whether the entity accessing the site is a human, and that information is used both to allow access to resources and to decide whether to use that entity's labels for the CAPTCHAs in the second set. The user's response to the second set is used to determine reasonable human responses to that CAPTCHA and assessing how vulnerable the CAPTCHA is for attacks. Once a CAPTCHA in the second category has been sufficiently vetted, it is moved to the first category. When the CAPTCHA is moved to the first category, a solution or a solution set is associated with it. That is, the decision to move the CAPTCHA can be made after a statistically significant number of solutions to the second test have been received. Then, either the highest scoring solution is chosen as a correct solution, or a set of most commonly received solutions is chosen as the correct solution and a user entering any of the solution from the set, is granted access. [0053] While the invention has been described with reference to particular embodiments thereof, it is not limited to those embodiments. Specifically, various variations and modifications may be implemented by those of ordinary skill in the art without departing from the invention's spirit and scope, as defined by the appended claims. For example, each of the novel types of CAPTCHAs described can be incorporated in a number of different ways into more complex CAPTCHAs, like ones that ask the user to determine the odd one out, or the correct sequence, same set or different, topic of a set, etc. Similarly, hybrid CAPTCHAs that combine features from animated, interactive, and video CAPTCHAs are also possible. Additionally, as noted before, the CAPTCHAS can be made to have multiple layers. FIG. 9 depicts an example of a CAPTCHA having multiple layers. One layer comprises generally a background, such as a “wallpaper” having diamond shape pattern. Another layer includes the encoded solution, e.g., “A 2 C 5” illustrated in FIG. 9 . Yet another layer comprises various obstruction elements, such as “floating disks” illustrated in FIG. 9 . Any of the layers may be set stationary or movable. Also, as in the above examples, it can be set that none of the encoded solution element is ever completely exposed or, conversely, it can be set that each element of the encoded solution is an incomplete element, such as an incomplete letter or numeral character. [0054] It should also be appreciated that the usage of “background” and “foreground” layers is meant for easy understanding of the various embodiments of the invention. However, the various embodiments are not necessarily restricted to usage of layers per se. Other methods can be used that do not define layers, but which provide the same functions and results as in the illustrative embodiments. [0055] FIG. 10 depicts another example of an embodiment having multiple layers. However, in FIG. 10 the encoded solution is an image, rather than a typographical character. The user is then required to enter a word corresponding to the image. As before, the various layers can be set in motion automatically, such as in an animation clip, or in response to a user input. The user may also “pick and drag” any layer or one movable layer in order to properly expose the encoded solution.
An automated test to tell computers and humans apart is disclosed, comprising displaying on a computer screen an animation comprising of a foreground and a background, one of the foreground comprising a plurality of typographical characters and the other comprising partial obstruction of the typographical characters, and wherein the animation comprises relative motion between the background and foreground. The automated test may comprise displaying on a computer screen an image, and requiring the user to perform operation on the image to resolve an encoded solution. The test may also comprise displaying on a computer screen a video clip, and requiring a user to provide an input corresponding to subject matter presented in the video clip.
6
CROSS-REFERENCE TO RELATED APPLICATION This application is a continuation of copending International Application No. PCT/EP01/14909, filed Dec. 17, 2001, which designated the United States and was not published in English. BACKGROUND OF THE INVENTION Field of the Invention The invention relates to a method and a configuration for removing moisture from items of clothing. Numerous methods of, and configurations for, removing moisture from items of clothing are known. For example, it is known for items of clothing that are to have moisture removed from them to be centrifuged, in particular, in a drum provided with openings, in order for liquid absorbed by the items of clothing to be separated off. It is also known for liquid to be squeezed out of items of clothing. These known methods, however, have the disadvantage that the fabric of the items of clothing is badly creased, which renders subsequent pressing or ironing more difficult. It is additionally known for wet items of clothing to have moisture removed from them, and/or to be dried, by hot air, although this, disadvantageously, requires a large amount of energy. SUMMARY OF THE INVENTION It is accordingly an object of the invention to provide a method and configuration for removing moisture from items of clothing that overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that, with low energy-related outlay, extracts moisture from the items of clothing without the latter suffering any adverse effects. With the foregoing and other objects in view, there is provided, in accordance with the invention, a method of removing moisture from items of clothing, including the steps of bringing an item of clothing into contact with at least one absorbent body made of an absorbent material and subsequently separated the item of clothing from the at least one absorbent body. Using an absorbent material allows moisture to be extracted from the item of clothing with low energy-related outlay. A suitable configuration of the absorbent body here means that the item of clothing is not adversely affected. This is particularly easy because absorbent materials for producing the absorbent body are generally soft in any case so they do not adversely affect the item of clothing. As such, there are no impressions produced in the item of clothing and there is only a small amount of creasing, if any at all. Subsequent pressing is, thus, simplified to a considerable extent. If the absorbent body is made of a hard material, the surface that is brought into contact with the item of clothing can be configured in a smooth manner. The absorbent body may be made, for example, of foam that has cells into which liquid from the item of clothing is drawn on account of the capillary action. It is also possible for the absorbent body to be made of a woven fabric or of a nonwoven or felt material made of fibers, in particular, microfibers. An absorbent body made of a woven fabric may have additional absorbency-increasing fibers that, for example, are applied by flock coating or are worked therein in the form of loops. An example of a woven fabric provided with loops is terry cloth, it also being possible to use Turkey toweling in which the loops have been cut open. The absorbent body, advantageously, contains hydrophilic materials. In particular, in the case of fibers, the latter may be, for example, cotton or polyamide fibers. The moisture that is to be removed may be, in particular, washing liquid or rinsing liquid for rinsing out washing liquid, these being used during washing of the items of clothing. In accordance with another mode of the invention, following contact with the item of clothing, the absorbent body has moisture removed from it and/or is dried. As a result of the previous transfer of the moisture from the item of clothing to the absorbent body and the removal of moisture from the absorbent body rather than the item of clothing, it is possible to use numerous advantageous moisture-removal methods because the item of clothing need not be taken into consideration. For the purpose of removing moisture from the absorbent body, it is possible to use any known method that does not destroy the absorbent body. It is possible here, in particular, to use mechanical pressing methods because the absorbent body is either already resistant to mechanical pressure in any case or can be made resistant with low outlay. Furthermore, the absorbent body may be configured as a cost-effective exchangeable part so that wear of the absorbent-body material is acceptable. Mechanical pressing methods have the advantage that they can be implemented with straightforward measures and remove moisture or liquid with low energy consumption. It is also conceivable here, however, to remove moisture from the absorbent body by the use of heat and/or by dry air. A continuous process is, advantageously used, to bring the item of clothing into contact with an absorbent body, which, then, has moisture removed from it again. It is possible here for an absorbent body to be brought into contact with an item of clothing, and have moisture removed from it, section by section. For such a purpose, it is possible to use, in particular, a circulating continuous absorbent body, the movement path of which runs from an item of clothing to a moisture-removal device and back again. For example, use may be made of a belt-like absorbent body that circulates through deflecting rollers, it being possible for the items of clothing that are to be dried to be moved between a deflecting roller and a pressure-exerting configuration, in particular, in the form of a pressure-exerting roller. If, in addition, the items of clothing are moved at the same speed as the surface of the absorbent body, it is, thus, possible to achieve the situation where the absorbent body rolls on the item of clothing, this avoiding relative movement between the absorbent body and the item of clothing and, thus, abrasion of the item of clothing. In accordance with a further mode of the invention, the absorbent body is provided with a plurality of sections and individual sections of the absorbent body are successively brought into contact with the item of clothing, separating the section from the item of clothing, and removing moisture from the item of clothing. In accordance with an added mode of the invention, the absorbent body is provided as a continuous strand and the absorbent body is circulated to successively move the individual sections of the absorbent body to the item of clothing and to a configuration for removing moisture from a section of the absorbent body. In accordance with an additional mode of the invention, moisture is removed from the absorbent body by squeezing. In accordance with yet another mode of the invention, the at least one absorbent body is rolled on the item of clothing. It is also possible to provide an absorbent body that is large enough to be used, section-by-section, to remove moisture from all the items of clothing in a batch. Those sections of the absorbent body that are used, or brought into contact with an item of clothing, are moved to a collecting location. Following removal of moisture from the last item of clothing in the batch, the absorbent body can be dried as a whole or section-by-section. In the case of this method, a very high level of moisture-removal action can be achieved for all the items of clothing in the batch because it is always possible for a completely dry absorbent-body section to be brought into contact with an item of clothing. It is also possible, here, for the absorbent body to be dried slowly in the ambient air until the configuration is next used. For such a purpose, it is possible for a connection between the collecting location of the absorbent body and the exterior to be open or for the collecting area to be ventilated. In accordance with yet a further mode of the invention, the item of clothing can be brought into contact with an absorbent body from different sides. It is, thus, possible for a larger surface area of the item of clothing to be brought into contact with absorbent bodies and, consequently, for the moisture-removal action to be improved. To bring the item of clothing and the absorbent body into contact with one another, it is also possible for the item of clothing to be pressed against the absorbent body by a gas jet, in particular, an air jet. This avoids impressions of solid objects on the item of clothing. In accordance with yet an added mode of the invention, the item of clothing is subjected to action of at least one gas jet acting transversely to a surface of the item of clothing following contact with the absorbent body. Following the moisture removal with the aid of the absorbent body, the item of clothing may be subjected to the action of gas jets or compressed-air jets to be pressed. Using a gas jet, which is, preferably, an air jet and exerts a force on the item of clothing that is to be pressed, makes it possible to achieve a pressing action with low outlay, this pressing action, in addition, having no adverse effects on the item of clothing. The gas jet can push the fabric of the item of clothing in at certain locations or subject the entire item of clothing to a tensile force. As a result, the item is tensioned. As such, any creases that may be present are pressed. This pressing action of the gas jet may be enhanced by the fabric of the item of clothing being relieved of tensioning prior to the pressing operation or at the beginning of the pressing operation, by the fabric of the item of clothing being dampened and heated. For such a purpose, water vapor may be mixed in with the gas jet and, in this way, directed onto the fabric. Furthermore, the item of clothing can be sprinkled with water, it being possible for the water to be sprinkled by the nozzle that directs the gas jet against the item of clothing or by a dedicated nozzle, which is not used for producing the gas jet. The at least one gas jet necessarily subjects the item of clothing to a force. The item of clothing may, thus, be disadvantageously moved and possibly creased in the process. This can be prevented, for example, by using a gas jet that, although having a high outflow speed, has a small diameter. As a result, the item of clothing is not subjected to any large force and significantly changed in position, by the gas jet, although, over a small region of the item of clothing, it is possible to achieve a high level of tensioning action for the fabric and, thus, a good pressing action. Provision may be made here, in the case of hanging items of clothing, for the deflection on account of the gas jet to be compensated for at least in part by drawing the measures for hanging the item of clothing some way in the direction of the nozzle out of which the gas jet flows. The item of clothing is, advantageously, supported as it is subjected to the action of the gas jet. This can prevent the item of clothing from being moved by the force of the gas jet. It is, thus, also possible to use a stronger gas jet and, thus, to achieve a better pressing action. The support may be provided by fixed supports, for example, at least one supporting surface. If the item of clothing is moved, for example, to pass through a number of treatment stations, such supports may also be set up such that they can move along with the item of clothing. For example, use may be made of at least one supporting roller that is mounted in a rotatable manner about an axis that is oriented at least substantially perpendicularly to the movement direction of the item of clothing. In accordance with yet an additional mode of the invention, the item of clothing is supported by a gas jet. In such an embodiment, the item of clothing is subjected to the action of at least one gas jet from both sides. This makes it possible to avoid impressions in the fabric that can occur in the case of solid supports. Furthermore, the pressing action is enhanced because a force is exerted by a gas jet from both sides. The gas jets acting from both sides may be coordinated with one another, in particular, such that that section of the item of clothing that is located therebetween is deformed in a certain way to achieve a good pressing result. For such a purpose, the force exerted by the gas jets from both sides may be distributed over a certain surface area in each case with a non-uniform force distribution. The force distributions over the surfaces on the two sides may be set differently. As a result, in one section of the item of clothing, the force exerted on the section from one side is greater than the force exerted from the other, second side and, in an adjacent section, the force exerted from the second side is predominant. The item of clothing may, thus, be deformed in a defined manner, resulting in an assumption of, for example, an undulating form or raised sections form in the item of clothing on one side and the other. For example, it is possible to use, from one side, a gas jet that widens conically and is internally hollow. As a result, it exerts a force in an annular region on the surface of the item of clothing, and, from the other side, a gas jet that produces a force exclusively in a small punctiform or circular region, the punctiform or circular region being located within the annular region of the force exerted from the opposite side. As a result, the fabric of the item of clothing is tensioned and pressed between the annular region and the punctiform or circular region located therein. Instead of a punctiform or circular surface pressure from one gas jet, it is also possible to select a substantially linear surface pressure. It is generally possible, with the action of force in adjacent regions in different directions, for the fabric to be tensioned and pressed in these regions. The forces acting from both sides may be coordinated such that the item of clothing is retained in a certain local region and, in particular, is prevented from coming into undesirable contact with other parts. As a result, it is possible to prevent soiling or creasing. Because the force of a gas jet used decreases as the distance of the gas jet from the nozzle increases, the configuration, the orientation, and the outflow characteristics of mutually opposite nozzles directed toward one another can create a regulating system that tries to retain the items of clothing at a certain location between the nozzles. Provision may also be made here, however, for the location of the item of clothing or of a section of the item of clothing to be detected and for the location detected to be used as an input variable for a regulating device by way of which the gas jets acting on the item of clothing from both sides are regulated such that the item of clothing or the section of the item of clothing is always at a predetermined desired location or desired location region. The location may be detected by light barriers or reflected-light barriers, it also being possible to use other methods of measuring distance or detecting location, for example, by ultrasound. By virtue of the interaction of the forces exerted on the item of clothing from both sides and of the force distribution over the surface, it is possible for fabric of the item of clothing to be tensioned firmly, but without suffering any adverse effects, and, thus, for a good pressing action to be achieved. It is possible here for the force distribution and/or the overall force exerted from the individual sides to be changed over time. As a result, it is possible to achieve changing deformation that may have an advantageous effect on the pressing operation. During pressing, the gas jet for pressing the item of clothing may contain, in the first instance, heated air, and, then, initially substantially dry and heated air and, then, substantially dry and non-heated air. The hot air used at the beginning may be humidified to facilitate pressing. By the hot and dry air that is, then, used, the item of clothing is dried and, finally, cooled with cold air to reduce susceptibility to creases. It is possible to change the outflow speed, the volume flow, and/or the directional distribution of the gas jet during pressing by a gas jet. With the objects of the invention in view, there is also provided a method of removing moisture from items of clothing, including the steps of bringing an item of clothing into contact with at least one absorbent body in the form of a continuous strand, made of an absorbent material and having a plurality of sections, circulating the absorbent body to successively move individual sections of the absorbent body into contact with the item of clothing and to a configuration for removing moisture from a section of the absorbent body, separating the section from the item of clothing, subjecting the item of clothing to action of at least one gas jet acting transversely to a surface of the item of clothing following contact with the absorbent body, and removing moisture from the absorbent body following contact with the item of clothing. With the objects of the invention in view, there is also provided a configuration for removing moisture from items of clothing, including at least one absorbent body of an absorbent material and a contacting device adapted to contact an item of clothing with the at least one absorbent body and to separate the item of clothing from the at least one absorbent body. In accordance with again another feature of the invention, the absorbent body is of a microfiber material. In accordance with again a further feature of the invention, there is provided a transporting device moving a plurality of items of clothing successively in a direction of the at least one absorbent body and away therefrom. In accordance with a concomitant feature of the invention, the contacting device has a pressure-exerting roller spaced apart from the at least one absorbent body and the transporting device moves the items of clothing between the at least one absorbent body and the pressure-exerting roller. Other features that are considered as characteristic for the invention are set forth in the appended claims. Although the invention is illustrated and described herein as embodied in a method and configuration for removing moisture from items of clothing, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatic cross-sectional view of one embodiment of a configuration according to the invention for pressing items of clothing; and FIG. 2 is a fragmentary, cross-sectional view through a side of a configuration for receiving items of clothing for use in the pressing configuration according to FIG. 1 . DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown a configuration for washing, removing moisture from, and pressing all types of items of clothing, such as jackets, shirts, trousers, etc., having a cuboidal or cabinet-like housing 1 that serves for accommodating the items of clothing 2 that are to be pressed. Disposed within the housing 1 , on two opposite inner walls, is in each case one continuous transporting belt 3 that is mounted in a circulating manner, FIG. 1 showing one transporting belt 3 , in plan view. The two transporting belts 3 can be driven at the same circulatory speed and in the same, clockwise direction. Disposed between the transporting belts 3 are non-illustrated connecting struts on which are fastened hanging configurations 4 , on which the items of clothing 2 that are to be pressed are hung. The hanging configurations 4 are substantially in the form of a clothes hanger. As a result, all types of items of clothing can be hung thereon. The transporting belts 3 are disposed in the top region of the housing 1 and are in the form of a square. As a result, the items of clothing 2 can be moved upward on the left-hand side, to the right at the top, downward on the right-hand side and to the left at the bottom. At the bottom of the left-hand side wall of the housing 1 , two mutually opposite compressed-air nozzles 7 are disposed such that the items of clothing can be moved upward by the transporting belts 3 through the interspace between the compressed-air nozzles 7 . The compressed-air nozzles 7 are connected to a generator 5 , which has a fan and can produce air streams at different temperatures and different pressures. The generator 5 has an air inlet within the housing 1 and an air inlet 17 outside the housing 1 , which can take in fresh air. Disposed above the compressed-air nozzles 7 is a moisture-absorbing nonwoven 20 that is mounted, by two deflecting rollers, in the vicinity of the inner wall such that it can be driven like a conveying belt and moves parallel to the movement path of the items of clothing 2 . The moisture-absorbing nonwoven 20 is of a highly absorbent material and is driven at the same speed as the items of clothing 2 . As a result, the respectively inner section moves upward together with the items of clothing 2 . Disposed on that side of the transporting belt 3 that is located opposite to the moisture-absorbing nonwoven 20 is a pressure-exerting roller 21 that is provided with a compliant coating. The distance between the pressure-exerting roller 21 and the moisture-absorbing nonwoven 20 can be changed. As a result, it is possible either to compress the items of clothing 2 between the pressure-exerting roller 21 and the moisture-absorbing nonwoven 20 as they move through or to move the items of clothing 2 through the moisture-absorbing nonwoven 20 without contact. Provided at the bottom deflecting roller of the moisture-absorbing nonwoven 20 is a squeezing-out roller 22 , which is spaced apart from the bottom deflecting roller by such a small distance that the moisture-absorbing nonwoven 20 is compressed to a pronounced extent between the bottom deflecting roller and the squeezing-out roller 22 and, as such, liquid contained in the moisture-absorbing nonwoven 20 is squeezed out therefrom. Furthermore, the bottom part of the housing 1 contains a sump 18 in a false floor 25 , this being disposed at the bottom within the housing 1 and being formed such that all the liquid from the top part of the housing 1 collects at the bottom in the sump 18 , in which a lint filter 16 is disposed. The false floor 25 , furthermore, has the function of dividing off a dry space in which the generator 5 is accommodated. Also disposed in the dry space is a discharge pump 12 , of which the inlet opens out into the sump 18 and the outlet 13 leads outward and can be connected to a waste-water connection, in particular, a household one. Also disposed in the dry space, beneath the false floor 25 , is a washing configuration 19 , which is connected to the sump 18 and a non-illustrated clean-water feed and has a liquid pump and a heater. The washing configuration 19 is set up such that it can remove liquid either from the clean-water feed or from the sump 18 and can pass it on to different nozzles, it being possible for the liquid to be heated and, in particular, for liquid removed from the clean-water feed to be evaporated. Also provided in the washing configuration is a dispensing configuration, by which detergent can be dispensed into the housing 1 . Connected to this washing configuration 19 are wetting nozzles 9 , washing nozzles 10 , rinsing nozzles 11 and hot-steam nozzles 6 , these being disposed on the right-hand side of the housing 1 . The wetting nozzles 9 are supplied with clean water and serve for wetting dry items of clothing 2 . The washing nozzles 10 are supplied with, in particular, heated washing liquid, which is circulated, in particular, the sump 18 , and serve for washing the items of clothing 2 . The rinsing nozzles 11 are supplied with cold clean water and serve for rinsing the washing liquid out of the items of clothing 2 . The hot-steam nozzles 6 are supplied with heated water vapor obtained from clean water and serve for steaming the items of clothing 2 . FIG. 2 illustrates in section, by way of example, a hanging configuration 4 that has a hollow connecting section 23 and a hanger section 24 that is connected to the latter at the bottom, extends perpendicularly to the plane of the drawing and has a length that corresponds substantially to the width of an item of clothing 2 . The hanger section 24 is hollow and has openings distributed over its periphery. The hanging configurations 4 can be connected to the generator 5 or the washing configuration 19 through non-illustrated devices such that the interior of the connecting sections 23 and of the hanger sections 24 , like the hot-air nozzles 6 , can be supplied with hot air, washing liquid, rinsing liquid, or steam. Using the configuration according to the invention that is illustrated in FIG. 1 , items of clothing 2 can be first of all washed and dried and, finally, pressed, there being no need for the items of clothing 2 to be removed from the configuration. In the first instance, the items of clothing 2 are hung on the hanging configurations 4 . For such a purpose, it is possible for the hanging configurations 4 to be removed from the housing 1 , for the items of clothing 2 to be hung on the hanging configurations 4 and for these, then, to be hung in the housing 1 again on the connecting struts between the transporting belts 3 . Once the housing 1 has been closed, the wash cycle is initiated. For such a purpose, the transporting belts 3 are set in motion to move the items of clothing 2 through the housing in the clockwise direction. In the first instance, the items of clothing 2 are wetted with clean water by the wetting nozzles 9 . Thereafter, the items of clothing 2 are moved on to the washing nozzles 10 , by which they are sprayed with washing liquid, which is produced in the washing configuration 19 by virtue of detergent being dispensed into clean water. For such a purpose, the clean water is directed through a non-illustrated dispensing device, into which detergent can be introduced in powder and/or liquid form. The detergent, here, is dispensed into the housing 1 . As soon as there is a desired level of liquid in the housing 1 or a certain predetermined quantity of liquid has run in, the washing configuration 19 stops the feed of clean water and begins removing water from the sump 18 and directing it to the liquid nozzles 8 , the water being heated to a desired temperature. The water, which, in the meantime, has been mixed with the detergent, is, thus, circulated as washing liquid and can also be sprayed from the inside, through the hanging configurations 4 , onto the items of clothing 2 . In this step, dirt is rinsed out of the items of clothing 2 . Then, in a rinsing phase, the washing liquid is pumped out, by the discharge pump 12 , into a wastewater connection. Thereafter, the items of clothing 2 are rinsed to remove the washing liquid from them. For such a purpose, in a number of rinse cycles, clean water is pumped to the rinsing nozzles 11 and the water, together with the rinsed-out washing liquid, is pumped out by the discharge pump 12 . The rinsing action is enhanced, in that, at the end of each rinse cycle, the liquid feed to the rinsing nozzles 11 is interrupted and the compressed-air nozzles 7 are supplied with compressed air. When the items of clothing 2 are moved between the compressed-air nozzles 7 , they are compressed by the compressed-air jets. As a result, the rinsing liquid is forced out of them. As such, fewer residues of the washing liquid or contaminants remain following a rinse cycle. As a result, a smaller number of rinse cycles and less rinsing liquid is necessary. The air directed to the compressed-air nozzles 7 may also be heated here, as a result of which, the liquid absorbed by the items of clothing 2 flows out more easily and it is possible to enhance the water removal by compressed air at the end of the rinse cycles. So that a significant amount of liquid is squeezed out of the items of clothing, the compressed-air nozzles 7 are subjected to a very high pressure. Following the last rinse cycle, the items of clothing 2 have further moisture removed from them mechanically by the moisture-absorbing nonwoven 20 . For such a purpose, the distance between the moisture-absorbing nonwoven 20 and the pressure-exerting roller 21 is reduced to the extent where an item of clothing 2 moving through therebetween is forced against the moisture-absorbing nonwoven 20 by the pressure-exerting roller 21 . In the process, the highly absorbent material of the moisture-absorbing nonwoven 20 extracts further moisture from the item of clothing 2 . The moisture absorbed by the moisture-absorbing nonwoven 20 is squeezed out again between the bottom deflecting roller and the squeezing-out roller 22 . As a result, that part of the liquid-absorbing nonwoven 20 that has just come into contact with an item of clothing 2 always contains as little moisture as possible so that as much liquid as possible is extracted from the item of clothing 2 . This purely mechanical way of removing moisture does not require any heat, which disadvantageously requires a very large amount of energy to produce. As a result, with the aid of the moisture-absorbing nonwoven 20 , the moisture content of the items of clothing 2 can be reduced with particularly low energy-related outlay. Furthermore, using this way of removing moisture, on account of the absorbing action of the moisture-absorbing nonwoven 20 , a large amount of moisture can be extracted from the items of clothing 2 even with just a low contact pressure. As a result, the items of clothing 2 are not creased and, nevertheless, have moisture removed from them to a great extent. The contact pressure can be adjusted by changing the distance between the pressure-exerting roller 21 and the moisture-absorbing nonwoven 20 , particularly, in dependence on the fabric and thickness of the items of clothing 2 . The preliminary removal of moisture by the moisture-absorbing nonwoven 20 is followed by the drying and pressing step. The pressing, advantageously, takes place with a defined level of moisture in the items of clothing 2 . If the items of clothing have already had sufficient amounts of moisture removed from them by the moisture-absorbing nonwoven 20 , the items of clothing 2 may be pressed immediately following the preliminary removal of moisture by mechanical measures. If the preliminary removal of moisture by mechanical measures was not sufficient, the items of clothing 2 are dried to the suitable level of moisture, prior to pressing, with warm or hot air from the compressed-air nozzles 7 . For such a purpose, low-pressure heated air is directed to the compressed-air nozzles 7 . At the same time, the rear wall 15 of the housing is cooled with clean water from the clean-water connection. As such, the moisture extracted from the items of clothing 2 condenses on the rear wall 15 and runs into the sump 18 , from which it can be pumped out, together with the cooling water for the rear wall 15 , by the discharge pump 12 . There is air circulation within the housing 1 in this case, for which purpose the generator 5 takes in the air within the housing 1 . It is also possible for the items of clothing 2 to have moisture removed from them, until the desired level of moisture is reached, by the ventilation principle, in that, by a fan 14 , air is constantly blown outward from the interior of the housing 1 . As such, the moisture extracted from the items of clothing 2 is led outward, the generator 5 having to take in the air from the outside. This method, however, requires the configuration to be set up in a sufficiently ventilated area in order to discharge the moisture that is led outward. The two possibilities, of either condensing the moisture in the configuration and pumping it out or of leading it outward, allow an operator to decide between the two variants in accordance with the respective conditions. Condensing the moisture in the configuration has the advantage that the set-up area need not be ventilated. As a result, for example, in winter, there is, advantageously, no loss of energy for heating the set-up area. In summer, in contrast, it is possible to select the ventilation variant, which does not require any clean water for cooling the rear wall 15 and requires less energy for heating the dry air. Pressing takes place by virtue of the items of clothing being subjected to the action of hot-steam from the hot-steam nozzles 6 . As a result, the fabric of the items of clothing 2 is heated and relieved of tensioning. The items of clothing 2 are, then, guided between the two compressed-air nozzles 7 . As a result of the compressed air passing out of the compressed-air nozzles 7 , the fabric of the items of clothing 2 is tensioned and pressed, the pressing operation and the compressed-air jets used corresponding to the previous exemplary embodiment. Pressing takes place by virtue of the force to which the items of clothing are subjected by the compressed-air jets from the compressed-air nozzles 7 . This force may be adjusted, to produce the desired action, by the pressure of the air directed to the compressed-air nozzles 7 . In particular, the force is adjusted such that the items of clothing 2 do not flap about; rather, that section of an item of clothing 2 that is respectively located between the compressed-air nozzles 7 are held taut. The compressed air used in the pressing step has a lower pressure than the compressed air that is used for removing moisture at the end of the washing phase. During pressing, an excessively high air pressure may be disadvantageous if the items of clothing 2 are, thus, caused to flap about or crease. It is possible, for example, for the two compressed-air nozzles 7 , during pressing, to subject the items of clothing to differently distributed surface-area forces. As a result, the forces acting from both sides on a certain part of an item of clothing 2 do not cancel one another out. It is advantageous for the surface-area force profiles of the forces exerted by the two compressed-air nozzles 7 to complement one another. As a result, for example, in the regions in which a high surface-area force is produced by the left-hand compressed-air nozzle 7 , a low surface-area force is produced by the right-hand compressed-air nozzle 7 , and vice-versa. The forces, here, are such that the items of clothing are retained approximately centrally between the two compressed-air nozzles 7 . In this way, an item of clothing 2 may be subjected, by compressed air, to tensioning forces that tension, and, thus, press, individual fabric sections of the item of clothing 2 . This operation is repeated each time a certain item of clothing 2 is guided between the two compressed-air nozzles 7 . During this operation, steam may continue to be directed onto the items of clothing by the hot-steam nozzles 6 . It should be ensured here that the steam is only expelled at low pressure so as to not result in the items of clothing 2 flapping about and/or creasing. The items of clothing 2 are dried further during this pressing operation, the moisture being extracted, as has been described above, by condensing on the cooled rear wall 15 and being pumped out by the discharge pump 12 or being blown outward by the fan 14 . Following a certain period of time, the discharge of hot-steam from the hot-steam nozzles 6 is stopped. The items of clothing are, then, only subjected to the action of hot compressed air from the compressed-air nozzles 7 to finish drying them during pressing. As soon as the desired degree of dryness has been reached, the items of clothing are only subjected to the action of cold air to cool them, as in the previous exemplary embodiment. Thereafter, the items of clothing 2 can be removed from the housing 1 . As soon as drying of the items of clothing 2 has been finished, the items of clothing are moved further in the housing 1 , although only cold air is blown in through the compressed-air nozzles 7 . As a result, the pressed items of clothing 2 are cooled and become less susceptible to creasing because the fabric creases more easily when hot. Furthermore, the situation where an operator burns himself/herself on hot parts within the housing 1 is prevented. Following cooling of the items of clothing 2 and/or of the configuration, the items of clothing 2 can be removed. For the items of clothing 2 to be pressed without this operation being preceded by a wash cycle, the items of clothing can be dampened with a small amount of clean water from the wetting nozzles 9 . As a result, the fabric of the items of clothing 2 is relieved of tensioning. Thereafter, the items of clothing 2 can be pressed and dried as described above. The hot-steam nozzles 6 also make it possible for the items of clothing 2 to be pressed without being soaked beforehand. For such a purpose, items of clothing 2 that have, for example, already been washed and dried may be steamed in the configuration and, then, pressed and dried as described above. Furthermore, it is also possible for the items of clothing 2 to be pressed without steaming by the hot-steam nozzles. This is possible, in particular, if the items of clothing 2 have been washed beforehand and, following the preliminary removal of moisture, contain a certain residual level of moisture. In such a case, heated compressed air is, advantageously, directed to the compressed-air nozzles 7 to heat the items of clothing 2 and, thus, facilitate pressing.
Examples of dehumidifying processes for clothes include spinning, extracting the moisture by pressure, or drying the clothes using heat and air. To dehumidify the clothes gently and economically in terms of energy consumption, a method and apparatus for dehumidifying clothes includes bringing the clothes into contact with at least one absorption body of an absorbent material. Advantageously, a rotating absorbent body is used, its sections being continuously alternately brought into contact with an item of clothing and dehumidified by pressing.
3
CROSS REFERENCE TO RELATED APPLICATION [0001] The application claims priority to U.S. Provisional Application No. 60/708,063, which was filed on Aug. 12, 2005. BACKGROUND OF THE INVENTION [0002] This invention generally relates to a method of calibrating a magnetometer for a force sensor. More particularly, this invention relates to a method of calibrating a magnetometer for a force sensor for decreasing variability. [0003] A type of force sensor includes a transducer element that includes a magnetoelastic material containing two adjacent, oppositely circumferentially magnetically polarized axial regions, that each produces a magnetic field responsive to an applied force. This magnetic field is divergent in nature, for detection by a magnetometer circuit configured as a magnetic gradiometer. The generated magnetic field is then detected by the magnetometer that provides an output signal indicative of an applied force, and provides a minimal sensitivity to non-divergent extraneous magnetic fields, such as that of the Earth. [0004] A known magnetometer for application with such a force transducer includes independent magnetometer sections corresponding to an upper and lower axial section of the force transducer. The voltage difference of these two outputs provide the gradiometric senor output. Disadvantageously, although the individual magnetometer sections are produced to the same specifications, some differences occur and therefore can cause an asymmetrical sensitivity of the magnetic sense elements allowing non-zero sensitivity of the sensor to non-divergent magnetic fields. Such a phenomenon reduces the reliability and accuracy of the sensor. Further, hysteresis present within the magnetoelastic element may also prevent the transducer from returning to an original zero point after the application and subsequent removal of a force stimulus, also disrupting and reducing sensor accuracy. [0005] Accordingly, it is desirable to design and develop a method of calibrating a magnetometer that highly attenuates the sensitivity of the sensor to unwanted, extraneous magnetic fields. [0006] It is also desirable to design and develop a method of calibrating a force sensor magnetometer that corrects for hysteresis that may be present within the magnetoelastic sense element. SUMMARY OF THE INVENTION [0007] An example method of calibrating a magnetoelastic force sensor according to this invention includes the step of mating a force transducer with a magnetometer, applying a force to the force transducer at each of a multiple of defined calibration points, recording output signals indicative of a magnetic field generated at each of the defined calibration points communicated to each of the at least two channels, and determining a correction factor for each of the at least two channels based on the recorded output signals for each of the defined calibration points. [0008] An example torque sensor assembly calibrated according to the method steps of this invention includes a torque transducer with a magnetoelastic ring. The magnetoelastic ring produces a divergent magnetic field responsive to the application of torque. A magnetometer assembly includes at least two sense elements disposed adjacent to the torque transducer. [0009] The method includes the initial step of mating the force transducer with the magnetometer. The magnetometer includes at least two channels that receive the signals indicative of the magnetic field generated by the force transducer responsive to application of force. A series of known forces are applied to the torque transducer and recorded as calibration points. The calibration points are indicative of a magnetic field generated by the magnetoelastic ring. The gain of each of the channels is then matched so that when they are summed there is no sensitivity to ambient magnetic fields. Calibration coefficients are then determined for each channel such that the ratio between the gain in the channels is equal to a ratio between differential voltages obtained with the torque transducer assembly pointing sequentially toward a north and south polar, non-divergent magnetic field. [0010] Subsequently coefficients used for compensation for system hysteresis are calculated based on measured hysteresis of the system measured as the shift in zero-force output of the system prior to and after application of a stimulus force. [0011] Temperature compensation of the sensor system is also provided by allowing these coefficients to be modified according to the measured value of an associated temperature sensor. [0012] Accordingly, the method according to this invention provides for improved accuracy of a force sensor assembly and magnetometer. [0013] These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description. BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 is a schematic illustration of an example torque transducer according to this invention. [0015] FIG. 2 is a graph illustrating and example relationship between an applied force and an output voltage for an example torque transducer. [0016] FIG. 3 is a schematic illustration of example method steps for calibrating a torque transducer according to this invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0017] Referring to FIG. 1 , a torque sensor assembly 10 is schematically shown and includes a torque transducer 12 disposed about an axis 18 . The torque transducer 12 includes a shaft 14 with a magnetoelastic ring 16 . The magnetoelastic ring 16 produces a magnetic field 15 responsive to the application of torque on the shaft 14 . A magnetometer assembly 11 includes an inductor 21 disposed adjacent the torque transducer 12 that is magnetically saturated by a coil assembly. The coil assembly includes upper inner and outer coils 25 , 27 and lower inner and outer coils 24 , 26 . The inner coils 25 , 24 are configured to generate a magnetic field equal and opposite to a magnetic field generated by the outer coils 26 , 27 . [0018] A controller 36 energizes the coils 24 , 25 , 26 , 27 with an alternating current to generate an alternating magnetic field. The alternating magnetic field causes a magnetic saturation of the inductor 21 . When a torque is applied to the torque transducer 12 , the generated magnetic field 15 is superimposed on to the inductor 21 . The superimposition of the magnetic field 15 causes an asymmetry in magnetic fields between upper coils 25 , 27 and the lower coils 24 , 26 . The asymmetry is detected as a voltage signal across nodes 28 , 30 . The voltage signals 32 , 34 are then utilized to determine a magnitude of applied torque. [0019] Accurate operation of the torque transducer assembly 10 depends on the alignment and calibration of the coil assembly with the torque transducer 12 . A method according to this invention provides for the accurate calibration of the torque transducer to the coil assembly and the controller 36 . This is accomplished by mating the torque transducer 12 with the controller 36 and then determining a series of calibration coefficients. [0020] Referring to FIG. 2 , calibration of the torque transducer 12 provides for the accommodation of hysteresis in the sensor assembly. FIG. 2 is a graph representing a relationship 48 between an applied force 58 , and a voltage output 56 . The application of a force in a first direction provides a relationship between force and output indicated by line 50 . The release of force from a high point results in another relationship indicated at 52 . A gap 54 between the relationship for the application of force 50 and the release of force 52 can cause undesirable inaccuracies. However, this gap 54 can be calibrated and accommodated by the method according to this invention. [0021] Referring to FIG. 3 , the method includes the initial step of mating the force transducer 12 with the magnetometer 11 as indicated at 60 . The magnetometer 11 includes at least two channels 33 , 35 that receive the signals 32 , 34 indicative of the magnetic field 15 generated by the force transducer 12 responsive to application of force. A first known force 20 is applied to the torque transducer 12 in a first direction as is indicated at 62 . This provides a calibration point. In this example the first force comprises a full-scale positive torque applied to the torque transducer 12 . The first force 20 is then released and the torque transducer 12 allowed to move back to a zero position as indicated at 64 . A voltage output is recorded at this zero-force point as another calibration point. A second force 22 is applied to the torque transducer 12 in a second direction opposite to the first direction and another calibration point is recorded as is indicated at 66 and 68 . In this example, the second force 22 is a full force in a negative torque direction. The calibration points are voltage values that are indicative of a magnetic field generated by the magnetoelastic ring 16 . The calibration points also reveal any difference that may be present between the actual applied force value 20 , 22 and the actual reading obtained from the torque transducer. [0022] The gain of each of the channels 33 , 35 can then be matched so that when they are summed there is no sensitivity to ambient magnetic fields. Output values are obtained with the torque transducer assembly 10 facing a magnetic north pole 40 and a magnetic south pole 42 ( FIG. 1 ) as indicated at 70 and 72 . Accordingly, calibration points are required for pointing the torque transducer assembly 10 toward magnetic north 40 and taking a calibration point. Further, the torque transducer 12 is then pointed in a direction indicative of magnetic south 42 and another calibration point determined. The calibration points are determined as an output value for each of the outputs 32 and 34 from each of the nodes 28 , 30 . [0023] A correction factor or bias is then determined as indicated at 74 such that the ratio between the gain in the channels 33 and 35 is equal to a ratio between differential voltages obtained with the torque transducer assembly 12 pointing toward the north 40 and south 42 . That is a gain for each of the two channels 28 , 30 is set such that a ratio between the first channel 28 and the second channel 30 is equal to a ratio between an output value with the torque transducer assembly 10 facing north and an output value with the torque transducer facing toward the south magnetic pole 42 . [0024] The method also includes the step of determining a hysteresis value based on the calibration values obtained from the first and second forces 20 , 22 as is indicated at 76 . This is accomplished by determining a span between output values 32 , 34 for each calibration point received by each of the two channels 33 , 35 . Utilizing the span, a calibration coefficient or correction value is determined as a percentage of the span. The determination of the hysteresis correction value includes combining the span with a backlash value indicative of a difference between a hysteresis-containing signal and a desired output value. [0025] The hysteresis correction values are determined using known mathematical compensation techniques such as Prandt-Ishlinskyi Operators. As appreciated, the specific mathematical techniques for determining the hysteresis correction factors are application specific and tailored to the specific torque transducer assembly 10 . [0026] The method also includes determination of a temperature coefficient of the sensor system. The determination of temperature coefficient provides a correction factor to accommodate operation at varying temperatures and the effects that such temperature changes have on output voltages to the channels 33 and 35 . Temperature compensation values are determined by obtaining temperature values at known time intervals along with voltage values. A thermal correction factor is then determined utilizing known relationships between temperature, resistance and voltage and applied to the outputs 32 , 34 . [0027] Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied to determine the true scope and content of this invention.
A method of calibrating a magnetoelastic force sensor includes the steps of mating a force transducer with a magnetometer, applying a force to the force transducer at each of a plurality of defined calibration points, recording output signals indicative of a magnetic field generated at each of the defined calibration points communicated to each of the at least two channels, and determining a correction factor for each of the at least two channels based on the recorded output signals for each of the defined calibration points.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to pipe joints with premium threads and more particularly to joints used downhole in a producing well. The invention may be used with drill pipe, tubing or casing, all of which are referred to herein as "pipe". 2. Description of the Prior Art For many years couplings with threads formed on their inside diameter have been used to attach two relatively long sections of pipe to each other. Examples of such couplings are shown in U.S. Pat. No. 2,980,451 to W. B. Taylor et al; U.S. Pat. No. 4,004,832 to Eugene B. Connelly; and U.S. Pat. No. 3,497,246 to P. D. Weiner. U.S. Pat. No. 2,980,451 also discloses the use of elastomeric or polymeric seal rings to form a fluid barrier between the inside diameter of the coupling and the outside diameter of the portion of pipe disposed therein. U.S. Pat. No. 2,980,451 is incorporated by reference for all purposes herein. An alternative to the use of couplings has been to upset (enlarge the wall thickness by mechanical means) the end portions of sections of pipe. Appropriate male and female threads are machined on the upset ends to provide a pin means and box means respectively for joining sections of pipe with each other. Examples of such pipe joints and associated premium threads are shown in U.S. Pat. Nos. 3,489,437 to J. L. A. Duret and 3,100,656 to M. D. MacArthur. The premium thread and sealing system of the present invention can be satisfactorily used with either couplings or upset type pipe joints. COPENDING U.S. PATENT APPLICATIONS Applicants have the following patent applications pending for inventions related to pipe joints, couplings, and premium threads. ______________________________________Ser. No. Title Date Filed______________________________________324,234 Coupling November 23, 1981367,952 Pipe Joint April 13, 1982456,526 Pipe Joint January 7, 1983457,698 Pipe Joint January 13, 1983______________________________________ SUMMARY OF THE INVENTION The trend towards deeper and deeper wells, along with higher pressures and more severe environments found at these depths, has created a requirement for pipe joints with improved fluid seals. Metal-to-metal seals are particularly desirable for high pressure sour gas wells. When exposed to low pressure gas, metal-to-metal seals have a tendency to leak. Therefore, pipe joints with polymeric seal rings are desirable for this condition. Unfortunately, high pressure fluid has a tendency to excessively extrude polymeric seal rings from conventional pipe joints. During the operating cycle of many wells, pipe joints are exposed to both high and low pressures. The present invention includes a pipe joint with premium threads and a unique sealing system to block fluid leakage between the interior and exterior of the joint. The sealing system comprises a polymeric seal ring in an annular groove with annular metal-to-metal seals disposed on opposite sides thereof. By trapping the seal ring between the metal-to-metal seals, the pipe joint displays the desired fluid seal characteristics of both metal-to-metal seals and a polymeric seal ring similar to a conventional gasket and flange sealing system. One object of the present invention is to provide a pipe joint with a sealing system effective at both high and lower pressures and temperatures. Another object of the present invention is to provide a pipe joint with metal-to-metal seals on opposite sides of an annular polymeric seal ring whereby the metal-to-metal seals prevent undesired extrusion of the seal ring. Still another object of the present invention is to provide a pipe joint which can effectively seal against high differential fluid pressures from either the interior or exterior of the pipe joint. Additional objects and advantages of the present invention will be readily apparent to those skilled in the art after reading the specification and claims in conjunction with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a drawing in elevation with portions broken away showing the ends of two sections of pipe and a coupling which can be threadedly engaged with each section to form a pipe joint. FIG. 2 is an enlarged quarter-sectional view of a coupling incorporating the present invention. FIG. 3 is a drawing in elevation of the male or pin means of a section of pipe incorporating the present invention. FIG. 4 is an enlarged view in section with portions broken away showing the multiple fluid seals formed by engagement between the pin means and box means of a pipe joint incorporating the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT The components of a typical pipe joint, coupling 20 and portions of two pipe sections 40, are shown in FIG. 1. Each pipe section 40 has an identical pin means 41 with external threads 42 near its extreme end. Matching pin means 41 are also provided on both ends of each pipe section 40 (not shown). Each pipe section 40 is a long, hollow tubular member with longitudinal bore 43 extending therethrough. Coupling 20 is a relatively short, hollow cylinder with longitudinal bore 23 extending therethrough. Identical box means 21 with internal threads 22 are provided in each end of coupling 20. The internal configuration of coupling 20 is symmetrical with respect to internal flange 35. Internal threads 22 and external threads 42 are selected to be coengageable with each other to make up pipe joint 60, a portion of which is shown in FIG. 4. Couplings 20 are used to join a plurality of pipe sections 40 with each other to form a long tubing string which can extend from a wellhead (not shown) to a downhole hydrocarbon producing formation (not shown). Each coupling 20 maintains alignment of adjacent longitudinal bores 43 with each other and its own longitudinal bore 23. This alignment of longitudinal bores 43 and 23 provides a fluid communication flow path between the well surface and selected downhole locations. The present invention provides multiple seals within each pipe joint 60 to prevent fluid communication between the interior and the exterior thereof. Internal, annular groove 24 is machined in each box means 21 spaced longitudinally from the inner end of internal threads 22. A first annular sealing surface 25 is located between the inner end of internal threads 22 and internal groove 24. Second annular sealing surface 26 is located on the opposite side of internal groove 24. Both first sealing surface 25 and second sealing surface 26 taper inwardly towards the center of box means 21. The taper of sealing surfaces 25 and 26 is selected to form an acute angle of approximately three degrees with the centerline of longitudinal bore 23. The smallest inside diameter 27 of first sealing surface 25 is significantly larger than the largest inside diameter 28 of second sealing surface 26. Annular groove 24 is partially defined by inside diameters 27 and 28 as best shown in FIG. 4. Each pin means 41 has a first sealing surface 45 on its exterior spaced longitudinally from the end of external threads 42. A second sealing surface 46 is also provided on the extreme end of each pin means 42 spaced longitudinally from its associated first sealing surface 45. Sealing surfaces 45 and 46 of pin means 41 have matching tapers which form metal-to-metal seals with sealing surfaces 25 and 26 respectively of box means 21 during make-up of the pipe joint. Fluid tight engagement of sealing surface 45 with sealing surface 25 and sealing surface 46 with sealing surface 26 is best shown in FIG. 4. Polymeric seal ring 29 is preferably disposed in each annular groove 24 of box means 21. Shoulder 49 is provided on the exterior of pin means 41 between first sealing surface 45 and second sealing surface 46. Shoulder 49 is partially defined by the smallest outside diameter 47 of first sealing surface 45 and the largest outside diameter 48 of second sealing surface 46. Within the limits of acceptable machining tolerances, inside diameter 27 of box means 21 equals outside diameter 47 of pin means 41, and inside diameter 28 equals outside diameter 48. Shoulder 49 is sized to engage seal ring 29 and form a fluid barrier therewith during make-up of the pipe joint. Preferably, shoulder 49 is beveled relative to sealing surfaces 45 and 46. The amount of bevel is approximately thirty degrees as defined by acute angle b measured between the centerline of longitudinal bore 43 and the extension of shoulder 49. The fluid barrier formed by shoulder 49 and seal ring 29 will resist fluid communication therepast until the fluid pressure exceeds the pressure or force induced into seal ring 29 during make-up of the pipe joint. The induced pressure in seal ring 29 is a function of its volume, the volume of annular groove 24 and angle b of shoulder 49. The present invention allows each of these factors to be preselected to contain anticipated operating fluid pressures. A wide variety of materials may be used for the manufacture of seal ring 29 such as deformable plastics having characteristics similar to tetrafluoroethylene or elastomers having characteristics similar to polybutadiene/acrylonitrile. Preferably, matching torque shoulders 31 and 51 are provided within box means 31 and on the extreme end of pin means 41 respectively. Torque shoulders 31 and 51 define the limit of engagement of internal threads 22 with external threads 42. As shown in FIG. 4, torque shoulder 31 of box means 21 forms an acute angle with the interior of box means 21 adjacent thereto. Internal torque shoulder 31 is preferred because its inclined surface urges sealing surfaces 45 and 46 of pin means 41 into firmer contact with sealing surfaces 25 and 26 of box means 21. ENGAGING SEQUENCE Pin means 41 is inserted into box means 21 until threads 42 and 22 contact each other. Pin means 42 is then rotated to cause coengagement of threads 42 with threads 22. This threading motion causes pin means 41 to move longitudinally further into box means 21. The length and spacing of first sealing surface 45 and second sealing surface 46 are selected to engage adjacent sealing surfaces 25 and 26 of box means 21 before shoulder 49 contacts seal ring 29. Contact between first sealing surfaces 45 and 25 and second sealing surfaces 46 and 26 induces stress or pressure at the area of engagement due to their taper. This induced pressure is selected to be much greater than anticipated fluid pressure either exterior to or within pipe joint 60. Thus, two independent metal-to-metal seals are formed on opposite sides of annular groove 24. Continued rotation of pin means 41 will cause beveled shoulder 49 to contact seal ring 29. As previously noted, the present invention offers an opportunity to vary the induced pressure or compression placed on seal ring 29. Preferably, the induced pressure will be much greater than anticipated fluid pressures. Also, by first forming metal-to-metal seals on opposite sides of annular groove 24, seal ring 29 is prevented from excessive extrusion in either direction during make-up of pipe joint 60. This combination of metal-to-metal seals and polymeric seals allows pipe joint 60 to display the desirable characteristics of a conventional gasket and flange sealing system while maintaining an inside diameter and outside diameter compatible with downhole requirements. ALTERNATIVE EMBODIMENTS Threads 22 and 42 are shown in FIGS. 3 and 4 as the buttress type which are normally tapered at three quarters of an inch per foot. However, various other well-known thread profiles can be satisfactorily used with the present invention. Examples of such alternative thread profiles are shown in U.S. Pat. Nos. 2,980,451, 4,004,832, and 3,489,437. Box means 21 can be provided within the upset portion of a section of pipe as shown in U.S. Pat. No. 3,100,656 or 3,489,437. This type of pipe joint eliminates the requirement of a separate coupling. The present invention can be satisfactorily used with either type of joint. First sealing surfaces 25 and 45 and second sealing surfaces 26 and 46 can have contours other than tapers to establish sealing contact with each. For example, radii could be machined on first sealing surface 45 and second sealing surface 46 to engage adjacent sealing surfaces of box means 21. The principal requirement is that metal-to-metal seals be provided on opposite sides of seal ring 29. The foregoing disclosure and description of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made within the scope of the appended claims without departing from the spirit of the invention.
A pipe joint with premium threads having both metal-to-metal and polymeric seals to block fluid leakage through the joint. A polymeric seal ring is preferably carried within an annular groove in the box end. Metal sealing surfaces, each having a different inside diameter, are provided on opposite sides of the annular groove to form metal-to-metal seals with two compatible metal sealing surfaces on the exterior of the pin member. The joint is thus characterized by two metal-to-metal seals formed on opposite sides of the annular groove to trap the seal ring therebetween. The metal-to-metal seals cooperate to prevent undesired extrusion of the seal ring.
5
FIELD OF THE INVENTION [0001] The invention relates to image acquisition for magnetic resonance imaging (MRI), and in particular to a motion-resistant technique for image capture. BACKGROUND AND PRIOR ART KNOWN TO THE APPLICANT [0002] Magnetic resonance imaging has become established as a key technique for imaging the soft tissues of the body. MRI images are predominantly formed by the measurement of radio frequency signal emission during proton spin relaxation following an excitation signal to protons located in a magnetic field. The use of magnetic field gradients allows spatially encoded data to be acquired to form an image. The data are acquired in so-called “k-space”, related via Fourier transform to the physical space from where an image is acquired—different positions in “k space” correspond to spatial frequency and phase information. The task of forming an MRI image can be viewed as acquiring lines in k-space (“ky lines”) to span the entire k-space to be imaged, and then reconstructing the spatial image by Fourier transform. [0003] The physics underlying magnetic resonance imaging relies on the relaxation time of protons (or, occasionally, the relaxation time of other NMR active nuclei), and so acquisition of sufficient data to form an image takes significant time in relation to expected movement of a subject to be imaged, such as a human body. This problem is particularly acute when imaging structures within the thorax of a subject, as they are subject to cyclic motion from the subject's breathing during a typical timescale for image acquisition. The problem is further exacerbated in the field of cardiac imaging, where the beating of the heart adds a second cyclic motion to the problem. [0004] The problem has been addressed by the use of so-called ‘navigator acceptance’ imaging methods in which positional information is gathered effectively simultaneously with image data, but these have been hindered by the loss in scan efficiency which results from the changes in breathing pattern during a scan. The technique known as ‘phase ordering with automatic window selection’ (PAWS) provides a method which is resistant to changes in breathing whilst allowing the user the use of phase ordering to provide effective motion artefact reduction in an optimal time (Jhooti P, Gatehouse P D, Keegan J, Bunce N H, Taylor A M, Firmin D N. “Phase ordering with automatic window selection (PAWS): a novel motion-resistant technique for 3D coronary imaging”, Magnetic Resonance in Medicine, 2000, March, 43(3): 470-80.). The drawback of the PAWS technique is that images are only available once enough data has been acquired within the range of motion specified. Whilst the acquisition may terminate with the optimal scan time for the particular respiratory trace and acceptance window size, this optimal time may still be quite long. [0005] Other techniques such as the Diminishing Variance Algorithm (DVA) acquire the whole image before attempting to limit the respiratory motion (Sachs T S, Meyer C H, Irarrazabal P, Hu B S, Nishimura D G, Macovski A., “The diminishing variance algorithm for real-time reduction of motion artefacts in MRI”, Magnetic Resonance in Medicine, 1995, 34:412-422). Whilst DVA has the advantage of allowing scans to terminate at any point after the initial image has been corrected, the algorithm has been found to be less effective in subjects with a variable respiratory pattern (Jhooti et al, ibid). [0006] These navigator acceptance imaging methods are invariably compromised when the breathing pattern of a subject changes during the scan. Techniques such as PAWS have attempted to overcome such problems by the use of automatic sampling strategies which make no assumptions as to the final acceptance window. As all possible windows are treated with equal importance, the techniques have been shown to be effective in situations of changes of respiration whilst also allowing scans to terminate in an optimal time. However, as this technique focuses on its final optimal image, no image is available until this has been acquired. [0007] The DVA algorithm attempts to provide an image as soon as possible, and then to continually improve this image until a particular range of motion is achieved, or scan quality is deemed to be satisfactory. However, as this techniques makes a decision as to which range of motion will be accepted, and further acquisitions made accordingly, the situation is unsuitable in situations of respiratory change. A technique is therefore required to overcome these disadvantages. [0008] The present invention attempts to combine the noted benefits of the DVA and PAWS technique to provide a methodology that enables images to be reconstructed quickly, and with all further data acquisition reducing the acceptance window and improving image quality, whilst ensuring that a scan terminates automatically in an optimal scan time for a given acceptance window size regardless of respiratory pattern. SUMMARY OF THE INVENTION [0009] The invention provides improved scan efficiency by a ContinuousLy Adaptive Windowing Strategy, hence termed CLAWS. [0010] Accordingly, the invention provides a method of generating a magnetic resonance image of an object in cyclic motion, comprising the steps of: (a) defining a desired acceptance window corresponding to an extent of motion over which image data may be combined; (b) defining a series of position bands, together covering the total range of expected motion, to enable object positions within that range to be assigned to one of said bands, the range of motion corresponding to at least one of said bands being less than or equal to the acceptance window; (c) selecting a required image resolution, thus defining the number of ky lines to be acquired; (d) acquiring ky data and object position data according to a first phase of data collection, comprising the steps of: (1) generating an acquisition order for a first set of ky lines (the “first pass acquisition order”), such that each ky line to be acquired is included once in the order; (2) measuring the object position, and determining which position band corresponds to said object position; (3) substantially simultaneously with step (d)(2), acquiring ky data corresponding to the next ky line in the first pass acquisition order; (4) storing the object position and ky data so acquired; (5) repeating the method from step (d)(2) until data have been collected for all ky lines; (e) acquiring ky data and object position data according to a second phase of data collection, comprising the steps of: (1) measuring the object position, and determining which position band corresponds to said object position (the “current position”); (2) determining, from previously collected data, the ky line or lines (the “candidate lines”) for which the ky data collected closest to the current position (the “most proximate data”) is farthest away from the current position, and choosing this, or one of these candidate lines to be the next ky line to be acquired; (3) substantially simultaneously with step (e)(1), acquiring ky data corresponding to the next ky line so chosen; (4) storing the object position and ky data so acquired; (5) if all ky lines have been collected within the desired acceptance window, then creating and displaying an image using the ky lines, otherwise, (6) repeating the method from step (e)(1) onwards until all ky lines have been collected within the desired acceptance window, then creating and displaying an image using the ky lines within the acceptance window. [0027] Preferably, and where there is a plurality of candidate lines, the choice of which of the candidate lines is to be acquired is made according to at least one criterion selected from the group comprising: (A) counting the number of acquisitions already made for each candidate ky line, and selecting the candidate ky line or lines with the fewest acquisitions; (B) determining the average distance of previous acquisitions for each candidate line to the current position, and selecting the ky line or lines with the greatest average distance from the current position; [0030] Advantageously also, and where the distance between the farthest most proximate data and the current position is less than the desired acceptance window, the method further comprises the step of choosing the next line to be acquired according to at least one criterion selected from the group comprising: (A) determining the set of contiguous ky lines, corresponding to a position range equal to the desired acceptance window, having the most number of prior ky line acquisitions (the “most frequent window”); measuring the distance between the most frequent window to the most proximate data for each candidate ky line; and selecting the ky line or lines with the furthest most proximate data to the most frequent window; (B) determining the number of previous acquisitions for each of the candidate ky lines, and selecting the ky line or lines with the fewest acquisitions; and (C) determining the average distance of previous acquisitions from the current position for each ky line, and selecting the ky line with the largest average distance. [0034] Included within the scope of the invention is a method of generating a magnetic resonance image of an object in cyclic motion, comprising the steps of: (a) defining a desired acceptance window corresponding to an extent of motion over which image data may be combined; (b) defining a series of position bands, together covering the total range of expected motion, to enable object positions within that range to be assigned to one of said bands, the range of motion corresponding to at least one of said bands being less than or equal to the acceptance window; (c) selecting a required image resolution, thus defining the number of ky lines to be acquired; (d) acquiring ky data and object position data according to a first phase of data collection, comprising the steps of: (1) generating an acquisition order for a first set of ky lines (the “first pass acquisition order”), such that each ky line to be acquired is included once in the order; (2) measuring the object position, and determining which position band corresponds to said object position; (3) substantially simultaneously with step (d)(2), acquiring ky data corresponding to the next ky line in the first pass acquisition order; (4) storing the object position and ky data so acquired; (5) repeating the method from step (d)(2) until data have been collected for all ky lines; (e) acquiring ky data and object position data according to a second phase of data collection, comprising the steps of: (1) measuring the object position, and determining which position band corresponds to said object position (the “current position”); (2) determining, from previously collected data, the ky line or lines (the “candidate lines”) for which the ky data collected closest to the current position (the “most proximate data”) is farthest away from the current position; (3) if the distance between the farthest most proximate data and the current position is less than the desired acceptance window, then choosing the next ky line to be acquired from the candidate lines according to “Scheme B”, otherwise: (4) if more than one such ky line are determined to have equal farthest most proximate data, then choosing the next ky line to be acquired from the candidate lines according to “Scheme A”, otherwise: (5) choosing the ky line with the farthest most proximate data to be the next line to be acquired; (6) substantially simultaneously with step (e)(1), acquiring ky data corresponding to the next ky line so chosen; (7) storing the object position and ky data so acquired; (8) if all ky lines have been collected within the desired acceptance window, then creating and displaying an image using the ky lines, otherwise, (9) repeating the method from step (e)(1) onwards until all ky lines have been collected within the desired acceptance window, then creating and displaying an image using the ky lines within the acceptance window. wherein “Scheme A” comprises the steps of: (A1) counting the number of acquisitions already made for each candidate ky line; (A2) selecting the candidate ky line or lines with the fewest acquisitions; (A3) if only one such ky line is selected, then choosing that line as the next line to be acquired; otherwise (A4) determining the average distance of previous acquisitions for each candidate line to the current position; (A5) selecting the ky line or lines with the greatest average distance from the current position; (A6) if only one such ky line is selected, then choosing that line as the next line to be acquired; otherwise choosing any of these lines; and wherein “Scheme B” comprises the steps of: (B1) determining the set of contiguous ky lines, corresponding to a position range equal to the desired acceptance window, having the most number of prior ky line acquisitions (the “most frequent window”); (B2) measuring the distance between the most frequent window to the most proximate data for each candidate ky line; (B3) selecting the ky line or lines with the furthest most proximate data to the most frequent window; (B4) if only one such ky is selected, then choosing that line as the next line to be acquired; otherwise (B5) determining the number of previous acquisitions for each of the candidate ky lines; (B6) selecting the ky line or lines with the fewest acquisitions; (B7) if only one such ky is selected, then choosing that line as the next line to be acquired; otherwise (B8) determining the average distance of previous acquisitions from the current position for each ky line; (B9) selecting the ky line with the largest average distance; (B10) if only one such ky line is selected, then choosing that line as the next line to be acquired; otherwise choosing any of these lines. [0072] In this aspect of the invention, it has been found that the particular combination and ordering of steps in the method leads to especially rapid and reliable image acquisition. [0073] In any method described above, it is preferable that, following each acquisition of ky data in the second phase of data collection, an image is created and displayed using acquired ky data spanning the smallest range of object positions. More preferably, the method further comprises the step of allowing an operator, in us, to terminate image acquisition after displaying an image. [0074] In any method described above, it is preferable that the first pass acquisition order is chosen to initially collect data in the central portion of ky space, thereby allowing intermediate images to be created and displayed, albeit with a reduced spatial frequency bandwidth, before all ky lines have been acquired. [0075] Also in any method described above, it is preferable that the first pass acquisition order is chosen to initially collect data in a stepwise fashion across ky space, thereby allowing intermediate images to be created and displayed, albeit with a reduced resolution, before all ky lines have been acquired. [0076] In particularly preferred embodiments, the invention provides a magnetic resonance imaging heart monitor configured to use a method described above. [0077] Also included within the scope of the invention is a method of generating a magnetic resonance image substantially as described herein with reference to and as illustrated by any appropriate combination of the accompanying drawings. [0078] Whilst the above description uses the terminology of acquiring ky lines, it should be understood that the method also applies to the acquisition of groups of ky lines; this is the terminology used in FIG. 3 . [0079] Also, whilst the term “ky lines” has been used throughout this specification, and in the claims, it should be understood that this is not intended to limit the scope of the invention to any particular spatial direction, and should be taken to include other directions including those often referred to in the art as “kx lines” and “kz lines”. BRIEF DESCRIPTION OF THE DRAWINGS [0080] The invention will be described with reference to the accompanying drawings, in which: [0081] FIG. 1 s a graph showing the position of a target object to be imaged during a period of data acquisition. [0082] FIG. 2( a ) to 2 ( d ) are diagrams illustrating, schematically, data acquisition and formation of an MRI image; and [0083] FIG. 3( a ) to 3 ( c ) are flow diagrams illustrating embodiments of the method of the present invention. DESCRIPTION OF PREFERRED EMBODIMENTS [0084] The invention will be described with reference to one particular application of the method: the acquisition of magnetic resonance images of the heart, in the face of cyclic motion of the heart within the chest cavity caused by a patient's breathing. In this situation, movements of the heart are two-fold; firstly, the beating of the heart and secondly, movement of the organ throughout a breathing cycle. Motion artifacts caused by the beating of the heart may be readily removed by synchronizing the data acquisition cycles with the heart beat, i.e. data acquisition may be triggered by the cardiac cycle itself. This technique is known, and it is the second motion of the heart caused by breathing that remains to be solved. [0085] The position of the heart relative to the MRI scanner may conveniently be determined by measuring a position of a datum point in the body; typically this might be the position of the diaphragm, which moves little relative to the heart, and which can be measured by an MRI line image. FIG. 1 illustrates the movement of the diaphragm of a patient (and thus also the heart) during a period of data acquisition. It can be seen that, although the pattern of breathing, and thus movement, is relatively slow and regular over the first 20 or so acquisitions, breathing then becomes more erratic, and the pattern of movement changes over the acquisition period. [0086] In this case, a method of generating a magnetic resonance image of the heart was used employing the scheme outlined in FIG. 3 . [0087] FIG. 2( a ) illustrates the position after 16 acquisition cycles. It can be seen that data were acquired sequentially from ky line positions 1 through to 16 , and so the position data mirrors that of the object position shown in FIG. 1 for these acquisitions, in this example, each ky line position from 1 to 16 is represented by a column in the grid and each potential object position is then represented by a row in the grid labeled 1 to 36 . Each object position spans a distance of 1 mm, and thus the complete grid represents an object movement range of 36 mm. The filled-in squares in the grid represent object positions and ky lines for which data have been acquired. The set of such positions also marked with an ‘X’ represents a complete set of ky lines spanning the smallest range of object positions—i.e. the set of lines from which an image may be formed. It can be seen from FIG. 2( a ) therefore that after 16 cycles, an image may be formed corresponding to a range of object positions from row 2 to row 28 , i.e. spanning a distance of 27 mm. In this example, the desired acceptance window was set at 5 mm and so further acquisitions are required. In this example, it can be seen that the ‘most frequent window’, i.e. a window, the width of the desired acceptance window, that contains the most acquisitions, is located between positions 26 to 30 , this 5 mm window containing 5 acquisitions. [0088] FIG. 2( b ) illustrates the situation after 38 acquisition cycles. It can be seen in this figure that a complete image may be formed using ky data in rows 2 to 12 ; this is the minimum window that contains an acquisition for each of the 16 ky lines. In this case it spans a distance of 11 mm and so further acquisitions are required to generate an image within the desired acceptance window. [0089] FIG. 2( c ) illustrates the situation after 50 acquisition cycles. It can be seen from FIG. 1 that for acquisition number 50 , the diaphragm position was at 5 mm. Following the algorithm, it can be seen that the ky line with the furthest most proximate data is line 3 , having had its nearest acquisition at position 1 . However, this distance is within the desired acceptance window of 5 mm, and so a decision is made according to ‘Scheme B’ illustrated in FIG. 3( c ). In this case, ky groups number 2 and 4 are the only groups that have not been acquired within the most frequent window and, as ky group number 2 has been acquired more times than 4 (3 times, as opposed to twice) ky group number 4 is acquired in this instance. Following this acquisition, it can be seen that a complete image may be formed using ky data from object positions 1 to 7 , i.e. a window size of 6 mm. Again, this is still not within the desired acceptance window and so further acquisitions are required. [0090] FIG. 2( d ) shows the situation after 59 acquisition cycles. At this stage, it can be seen that a complete set of ky lines is available in positions 1 to 5 , i.e. corresponding to a position range of 5 mm. As this is the desired acceptance window size, data acquisition may be stopped and an image displayed.
A method of producing an MRI image of an object in cyclic motion by acquiring data in k-space according to the measured position of the object, and an analysis of data previously acquired. The invention also provides a magnetic resonance imaging heart monitor configured to use the method.
6
BACKGROUND OF INVENTION 1. Field of Invention This invention relates to circuit improvements, and more particularly to methods and circuits for reducing leakage currents in circuits. 2. Relevant Background A strong correlation has been shown to exist between the input vector applied to a logic cell and the leakage current through it. For example, for a 2-input static AND cell, it has been reported that the total drain to source leakage current when both the inputs are at logic 1 is 50 times greater than when the inputs are at logic 0. As process technologies continue to scale, leakage power becomes an increasingly important part of the total power dissipation of the chip. This is as threshold voltages and gate lengths are reduced in finer geometry processes, leading to increased leakage current. In addition, with significant gate oxide scaling, leakage current starts to occur through the transistor gates. Leakage power is especially crucial in portable devices, such as cell phones, where it can directly affect the operating time before which the device needs to be recharged. One solution that has been proposed is to determine whether a logic 1 or logic 0 value at the gate of a particular device is likely to minimize leakage of the device. Then, a vector is loaded into the latches of the circuit where leakage power dissipation is to be minimized. Thus, the latches apply a logic 1 or logic 0 value, as needed. This may be, for example, in response to a “standby” signal applied to or generated by the circuit. As integrated circuits become increasingly complex, mechanisms for testing have been designed into the circuits. A typical testing mechanism is a “scan-chain”. A scan chain typically includes a linked set of flip-flops, and usually, serially provided data is introduced into a flip-flop at one end of the chain and is clocked sequentially into the scan chain, over a number of clock cycles. The scan chain applies the test input (TI) data to various circuit elements, which produce a known output if operating correctly. If an output other than the expected known output is produced, an error in the circuit is indicated. The set of TI data that is clocked into the scan chain is often referred to as a vector, and, more particularly, is referred to herein as a test vector. The flip-flops are configurable to accept either the test vector in a test mode or data in a normal operating mode. Thus, a test enable (TE) signal is accepted by the flip-flops of the scan chain to essentially multiplex either the test vector or the actual data for application to the circuit. Another technique to reduce leakage power is to use large shut-off transistors which are provided to the power source. This technique requires significant layout overhead and also leads to power supply integrity issues. SUMMARY OF INVENTION One of the advantages realized by the invention is that by using the existing scan chain in the design, no modifications need to be made to the flip-flops or latches in the design. This means that there is no timing impact on the critical paths. Another advantage of the invention is that no extra area or power overhead is required by having to use more complex flip-flops or latches, which were required by the prior art. Still another advantage of the invention is that by not routing the sleep signal (also referred to as the “standby” signal) to each flip-flop, area penalties are avoided, as well as routing congestion and power dissipation in the design. These and other objects, features and advantages of the invention will be apparent to those skilled in the art from the following detailed description of the invention, when read in conjunction with the accompanying drawings and appended claims. The method and circuits of the invention provide a mechanism by which a set of low leakages vectors can be applied to a circuit when its inputs are not changing. The idea is that during the sleep period a set of low leakage vectors are loaded into the flip-flops of the design by using the scan chain (after which the clock signal provided to the flip-flops can be shut off.) While some extra power is dissipated in loading the low leakage signals it should be remembered that even if the sleep period lasts several seconds, it could represent many billions of clock cycles. Across so many cycles the power dissipated in loading the low leakage vectors would pale in insignificance compared to the total leakage power. Thus, according to a broad aspect of the invention, a circuit is presented that includes scan chain elements to contain a vector for selective application to circuit elements of the circuit. A vector memory contains a configuration vector which, when applied to the circuit elements, configures the circuit elements into a state in which a leakage current is reduced. A multiplexer selects the configuration vector for loading into the scan chain elements, and a clock generator clocks the configuration vector into the scan chain elements. In one embodiment, a sleep mode detector is provided to configure the multiplexer to select the configuration vector and to operate the clock generator to clock the configuration vector into the scan chain elements when a sleep mode of the circuit is detected. According to another broad aspect of the invention, a method is presented for reducing leakage currents in a circuit. The method includes clocking a configuration vector into scan chain elements for application to circuit elements within the circuit. The configuration vector configures the circuit elements into a state in which leakage currents are minimized. In one embodiment, the method includes detecting a sleep mode, and in response thereto performing the clocking. In another embodiment, the method also includes turning off clock pulses to the scan chain elements after the configuration vector has been applied to the circuit elements. According to still another broad aspect of the invention, a method for reducing leakage currents in a circuit is presented. The method includes determining a vector having first states which if applied to circuit elements of the circuit results in lower leakage currents than second states, detecting an operating mode of the circuit, such as a sleep or standby mode, and clocking the vector into scan chain elements of the circuit for application thereby to the circuit elements when the operating mode is detected. In one embodiment, the method also includes turning off clock pulses to the scan chain elements after the vector has been applied to the circuit elements. BRIEF DESCRIPTION OF DRAWINGS The invention is illustrated in the accompanying drawing, in which: FIG. 1 is an electrical schematic diagram of a circuit having a scan chain test capability together with a leakage current reduction circuit, in accordance with a preferred embodiment of the invention. And FIG. 2 is a state diagram showing an example of various states that may be assumed by a state machine in performing a method for reducing leakage currents in a circuit, in accordance with a preferred embodiment of the invention. DETAILED DESCRIPTION One embodiment 10 of the invention is shown in FIG. 1 , to which reference is now made. A preferred embodiment of the invention is particularly useful in conjunction with circuit or design 12 in which a scan chain test circuit 14 is already associated. In those circuits the scan-chain 14 is re-used to supply low leakage vectors to the flip-flops (not shown) of the circuit 12 . That is, in addition to retaining the original test uses for the scan chain 14 , the scan chain 14 is additionally used to contain a vector that reduces the leakage currents in the circuit elements of the circuit 12 , in a manner below described in detail. A typical scan chain 14 may include a large number of flip-flops; however, the scan chain shown includes only two flip-flop elements 16 and 18 , for brevity, it being understood that many such flip-flop elements may be included in the scan-chain 14 . The two scan-chain elements 16 and 18 shown are the same elements that would pre-exist in association with the circuit 12 with which the invention is employed. Typically, each flip-flop includes a D (data-in) input to which data is applied in normal operation, a TI (test-in) input to which a test vector is applied in test mode, and a TE (test-enable) input which controls the input to the flip-flop to be either the D input or the TI input. Thus, in normal testing operations, the scan-chain 14 is controlled by the TE signal 20 , which controls whether the TI input 22 or standard D input 24 is loaded into each scan-chain flip-flop 16 , 18 . In the circuit embodiment 10 shown, when a sleep or standby mode signal occurs, the scan-chain 12 is enabled by a LLE (low leakage enable) signal 28 in place of the normal TE signal. This is implemented by a simple multiplexer 30 , which receives the TI signal 20 on one input and the LLE signal 28 on another. The selection signal for the multiplexers 34 and 30 , as well as the LLE signal 28 is controlled by a finite state machine (FSM) 36 . Also, according to the invention, the data inputted into the flip-flops 16 and 18 of the scan chain 14 is an LLI (low-leakage input) vector 35 , instead of, the TI signal 22 that is used during scan testing. The LLI vector may be variously referred to herein as a low leakage input vector, a configuration vector, or a power control vector. This selection is also implemented with a multiplexer 34 , which receives the TI signal 22 on one input and the LLI signal 35 on another. Thus, a simple change at the input of the scan chain 14 can allow the scan chain 14 to load low leakage vectors in addition to scan testing vectors. The process of loading the low leakage vectors begins once a sleep signal is received or generated. The sleep signal may be generated, for example, in known fashion. One technique for providing the sleep signal may be, for example, on-chip, based on some time-out mechanism. Alternately, the sleep signal could be provided from off-chip sources. Those skilled in the art will recognize other sleep or standby mode signal generation techniques. In any case, once the sleep signal is received, the LLE signal 28 is invoked for the desired scan chain elements 16 , 18 , and the LLI vector 35 is scanned or loaded thereinto. The LLI vector 35 may be provided, for instance, from an on-chip memory device 37 , from an off-chip source (not shown), or from another source. Generally, a control signal from the FSM 36 would initiate the delivery of the LLI vector 35 , for example, by an enable signal on a line 26 . The FSM 36 may be used to ensure that the LLI inputs are serially available once the LLE signal 28 is turned on or selected via multiplexer 30 . Various states that may be included in the finite state machine 36 are exemplified in FIG. 2 , to which reference is now additionally made. The finite state machine 36 continually checks for a change of state of the sleep, or standby, mode signal, states 50 and 52 , and while the circuit is not in sleep mode, allows clock signals from the clock generator 40 to apply clock pulses to the flip-flops 16 , 18 via clock enable signal 38 applied to AND gate 42 . Once a sleep mode is detected in state 52 , the LLE signal is turned on, state 54 . In order to ensure that the right vector values are placed in their corresponding scan-chain flip-flops 16 , 18 , the LLE signal 28 must be activated for a number of cycles equal to the length of the scan chain 14 into which the LLI vectors are to be scanned. Preferably, this would include the entire scan-chain 14 , but in some applications, may include a sub-set of the scan-chain. Thus, the FSM 36 also receives (or generates) the sleep signal, and in response thereto controls the turn-on and turn-off of the LLI signal 35 by a signal on line 26 . As mentioned, since different scan chain in the design are likely to have different chain lengths the FSM 36 must ensure that each scan chain will be only active for a specific number of cycles. Accordingly, the finite state machine 36 checks the number of clock pulses against the desired number of scan flip-flops into which the vector is to be clocked, state 56 . After the low leakage vector, LLI, 35 has been loaded, the LLE signals for the scan chain are turned off, state 58 . In one embodiment of the invention, since there is no need to continue to clock the flip-flops 16 , 18 after the LLI vector 35 is loaded thereinto, the FSM controller 36 may then be used to send a clock gating signal 38 to the clock signals driving the scan chain flip-flops 16 , 18 . In the embodiment shown, for example, the clock signals from a clock generator 40 , which normally clock the flip-flops 16 , 18 , are compared, for example, in an AND gate 42 , with the normally high output 38 from the FSM 36 , state 60 . When the clock gating signal 38 from the FSM 36 goes low once the LLI vector 35 has been clocked into the flip-flops 16 , 18 , the clock signals are blocked from clocking the flip-flops 16 , 18 further. This may be performed in state 62 , in which the sleep mode is again monitored to ensure that it is still turned off. If it remains off, the flip-flops 16 , 18 are not clocked. This will lead to further power savings. On the other hand, if the sleep mode is turned off, the state machine returns to state 50 , removing the clock gating signal 38 , allowing the flip-flops 16 , 18 to once again be clocked. The FSM 36 can be modified to return to state 50 (the sleep mode off state) during states 54 , 56 , 58 or 60 if the sleep signal is deactivated. The actual implementation will depend on the minimum length of sleep state possible. This is likely to be significantly longer than the number of clock cycles required to load the LLI vector if, for example, the PLL needs to powered up at the end of sleep. The particular values of the LLI vector 35 that are applied to the scan chain may be pre-computed, for example based upon heuristic data or other data known about the particular devices in the circuit 12 to which they will be applied. It is assumed that a fully automated flow mechanism will be provided by which a memory to hold the LLI vectors 35 and FSM 36 will be generated once the logic is known. This is necessary as the input vectors that cause minimal leakage current are strongly dependent on the logical structure of the module. Thus, it can be seen that the solution presented herein has at least two major advantages. First, by using the existing scan chain in the design, no modifications need to be made to the flip-flops or latches in the design. Therefore, the use of the method and circuitry of the invention will have essentially no timing impact on the critical paths. Second, there is no extra area or power overhead in having to use more complex flip-flops or latches. By not routing the sleep or standby signal to each flip-flop, the area penalty, routing congestion and power dissipation in the design are avoided. Although the invention has been described and illustrated with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example, and that numerous changes in the combination and arrangement of parts can be resorted to by those skilled in the art without departing from the spirit and scope of the invention, as hereinafter claimed.
A leakage power control vector is loaded into existing test scan chain elements for application to circuit elements of a circuit in which the leakage currents are to be controlled. The vector is designed to configure the circuit elements into states in which leakage currents are reduced. A multiplexer selects the power control vector for loading into the scan chain elements, and a clock generator clocks the configuration vector into the scan chain elements. A sleep mode detector may be provided to configure the multiplexer to select the power control vector and to operate the clock generator to clock the power control vector into the scan chain elements when a sleep mode of the circuit is detected.
6
FIELD OF THE INVENTION The present invention relates to a packing box made of cardboard or other packing material and more particularly to a packing box with a self-lockable closure and a packing method therefor. BACKGROUND OF THE INVENTION Packing boxes made of cardboard comprising a bottom portion including a rectangular bottom plane and three adjacent sides connected by a connecting strip to a lid portion including a rectangular top plane and three adjacent sides are well known. This type of box is used, in general, by bakers for boxing cakes or by clothing stores for boxing garments. Such boxes may have, on one side thereof, a locking mechanism including a flap associated with a closing element constituting both a handle and a latch for keeping the box closed. In order to use such a box it is necessary to manually close the lid and to subsequently extract the closing element which simultaneously provides both a handle and a locking system for the box. These packing boxes require sequential manual operations which cannot be made to be automatic in order to close and lock the box. Other packing methods that allow for easy closure are known in the art. Such methods often require a tie, made of either string or ribbon, or some other means for surrounding the package to keep it closed. This tying operation can become burdensome and expensive for packaging a large series of objects. Thus, a primary object of the present invention is to provide a packing box of simple construction which locks merely upon closing, requiring no tying or other manual manipulation to ensure locking. This object is achieved by providing at least one of the bottom sides of the above-described cardboard packing box having a pair of connected planes with adjacent sides with a flap and also providing a side of the lid portion with flap holding means for receiving the flap. The side of the lid portion opposite the bottom side provided with the flap is further provided with an opening for allowing fingers to pass through to unlock the flap when the box is folded to form a cubic volume. The flap and flap holding means of the present invention ensure that the box is automatically prevented from opening without outside intervention when the lid is snapped into placed over the bottom portion. SUMMARY OF THE INVENTION A packing box is provided with a simple and automatic locking system by means of an interactive flap and flap holding combination. In general, but also more particularly when the packing box is made of thin cardboard or any thin material, it is preferable to further provide a guide means for the flap, permitting precise closing as well as secure locking. Indeed, without a guiding means, the flap might be permitted to pass through the flap holding means in such a way that locking would be poorly ensured. The present invention also effectively overcomes this type of disadvantage by providing a packing box wherein the flap is systematically guided into an insured locking position regardless of the thickness or type of cardboard used. The self-locking packing box of the present invention is characterized by a flap, cut to match a flap holding means wherein the flap is provided with integral support means cooperating with guide means for guiding the flap into the flap holding means. When the lid of the box is placed in a closed position, the support means of the flap slides along the guide means until the flap is locked into place by the flap holding means. After the flap has been locked into place, the support means remain in place against the lateral sides of the flap holding means, providing further structural support to the flap. The flap is caused to be guided laterally when the lid portion is positioned over the bottom portion, such that the flap is prevented from rotating until it snaps into place, providing a secure and effective locking mechanism for the box. According to one essential characteristic of the invention, the base of the flap adjacent to the side is wider than the width of the opening of the flap holding means, providing support means for the flap by supporting the flap on either side thereof along the lateral walls of the flap holding means. The lateral walls also provide guide means for guiding the flap into the holding means. According to one preferred, but non-limitative application of the present invention, the flap, connected to the box along a folding line, is configured essentially in the shape of a "T" defined by the intersection of the surfaces of a first rectangular sector adjacent to the folding line and a second adjoining rectangular sector defined by a smaller surface area than that of the first rectangle, wherein the second adjoing rectangular sector is symmetrically narrowed along both sides thereof. In this manner, the first rectangular sector of the flap slides along the guide means, coming to rest thereon after locking is achieved. The description of the flap as an essentially T-shaped configuration must be construed very broadly, as the transition between the narrowed and non-narrowed parts of the flap may be sharp such that there is a discontinuity in the flap to yield a strict "T" shape, or may be gradual such that the flap has, for example, the shape of an isosceles trapezoid. Locking is accomplished by a slight rotational movement in the flap along the folding line when the lower end of the narrowed part of the flap is released into the flap holding means by reaching the horizontal opening thereof. This slight rotational movement ensures that the lower end of the flap moves into, and remains in contact with, a depression, albeit slight, formed by the horizontal opening of the flap holding means. According to various embodiments of the present invention, the packing box may have several locking devices disposed respectively on each of the sides thereof. Another purpose of the present invention is to prevent the box from being inadvertently opened after self-locking. This goal is achieved by providing a means for allowing fingers or other objects to push the flap out of the locked position, being composed of a scored orifice which must be broken in order to allow the lid to open. Yet another goal of the invention is to offer a fully automated packing method for products with automation being facilitated by machine-operated lateral guidance of the flaps to insure secure locking thereof. This goal is achieved through an automated packing process utilizing a cushion made of plastic or another shock absorbing material, cut to a desired size in order to fully surround the product wherein the cross-section of the cushion includes flap holding parts perpendicular to the length of the cushion. The cushion can also include openings along its face, constituting pivoting means to facilitate folding thereof. Packaging is accomplished by placing a product to be packaged above a reception region on a cushion of given length, the reception region being located directly above the packing box according to the present invention such that in the packing box can receive the product placed within the cushion, the cushion/product assembly thus inserted into the packing box. The cushion automatically deforms as it is introduced into the packing box so that the sides of the cushion completely surround the sides of the product and the top most side of the cushion is folded over the product. Finally, the lid portion of the packing box is folded over the bottom portion and the flaps lock into place in the flap holding means. DESCRIPTION OF THE DRAWINGS Other characteristics and advantages of the present invention will become clear from reading the description hereinbelow with reference to the attached drawings, wherein: FIG. 1 shows a top view of the cardboard strip which, after folding, constitutes the packing box of the present invention; FIG. 2a is a partial cross-sectional view of one of the sides of the box of the present invention and the locking system thereof; FIG. 2b is an exploded view of the locking system of the present invention; FIG. 3 is a perspective view of the box of the present invention; and FIG. 4 shows the packing process of the present invention. DETAILED DESCRIPTION OF THE INVENTION The packing box of the present invention is shown in FIG. 3, comprising a bottom portion including a bottom plane (114) having three adjacent sides (1145, 1141, and 115) forming the outer and front sides of the bottom portion of the box. This bottom plane (114) is connected by a connecting side (110) to a lid portion including a top plane (100) having three adjacent sides (101, 105, and 111) forming the outer and front sides of the lid portion of the box. To form the packing box, the lid portion is folded over the bottom portion such that the bottom and lid portions, together with the connecting side, define the periphery of the box. In one embodiment of the invention, as shown in FIG. 3, the bottom portion of the box is provided with a flap (1150) on the front side (115) cooperating with a matching flap holding means (1110) formed in the front side (111) of the lid portion of the box providing a closing system therefor. In another embodiment, the box may have two side flaps (11450 and 11410) disposed one on each lateral side (1145, 1141) of the bottom portion such that each flap is positioned opposite lateral flap holding means (104, 108) formed in the corresponding lateral sides (101, 105) of the lid portion. Finally, in another embodiment, the box closing system may be composed of three flaps, each positioned on each side of the bottom portion of the box, each flap being associated with corresponding flap holding means in the lid portion of the box. The box shown in FIG. 3 is formed from a strip of cardboard, cut as shown in FIG. 1, having reference numerals corresponding to those of FIG. 3. The cardboard strip comprises a first plane (100) constituting the top of the lid portion, delimited by folding lines (1004, 1005, 1006 1007). Folding line (1006) links the first plane (100) to a strip (111) which constitutes the front of the lid portion. Two lateral projections (112, 113) extend from the front side (111) of the lid portion at folding lines (1112, 1113) respectively. Folding line (1004) links the first plane (100) to a strip (110) constituting the connecting side, joining the lid portion to the bottom portion of the box. This connecting strip (110) corresponds to the width, length and height of the box. Folding line (1007) joins right lateral side (101) to plane (100). This right lateral side (101) is further divided by two folding lines (103), parallel to folding line (1007), forming a peripheral strip (102) such that peripheral side (102) is folded over side (101), peripheral side (102) forms the exterior side of the box while side (101) forms the interior side of the box. Peripheral strip (102) is provided with a notch (104) opening outward and having dimensions greater than the dimensions of the narrow part of associated flap (11410) which will be described later. Peripheral strip (102) further includes a pair of tabs (1020) and (1021), adjacent to the two opposite sides of notch (104), and having dimensions corresponding to indentations (1000, 1001) in folding line (1007). Finally, strip (101), which constitutes the right exterior side of the box is provided with a hole (1010) in the shape of a rounded rectangle whose function, as will be seen later, is to allow passage of a person's fingers or any other projecting apparatus in order to unlock the box. The left side of the box is constructed similar to the above described right side wherein strip (105), folding lines (107) and peripheral strip (106) make up the box side, and peripheral strip (106) includes a notch (108) having adjacent tabs (1062, 1063) for insertion into corresponding indentations (1002, 1003). In order to form the box as shown in FIG. 3 from the cardboard strip of FIG. 1, peripheral strips (102, 106) are folded inward along folding lines (103, 107) respectively. As previously described, strips (102, 106) form the interior sides of the box and strips (101, 105) form the exterior sides of the box. Projections (112, 113) are folded between interior sides (102, 106) and exterior sides (101, 105) and front side (111) is folded along line (1006). As can be seen in FIG. 2a, the outer edges of projections (112, 113), perpendicular to folding lines (1112, 1113), are positioned between folding lines (103, 107). Tabs (1020, 1021, 1062, 1063) are inserted into indentations (1000, 1001, 1002, 1003), respectively, in order to hold the assembly together. The bottom portion of the box is formed by connecting side (110) joined to second plane (114) via folding line (1100). Plane (114) is delimited by a second folding line (1151) parallel to line (1100) and adjacent to front side (115). Extending from both sides of front side (115) are projections (117, 118) joined to front (115) by folding lines (1157, 1156), respectively. Strips (1141, 1142) extend from plane (114) at folding line (1149), making up one exterior and interior side, respectively, joined by folding lines (1143). Strips (1145, 1146) extend from plane (114) at folding line (1148), making up another exterior and interior side, respectively, connected together by folding lines (1147). Outer sides (1141, 1145) are provided with flaps (11410, 11450), respectively, connected to the box at folding lines (1143, 1146) respectively. Interior sides (1142, 1146) include end tabs (11420, 11421) and (11460, 11461), respectively, for engagement with indentations (11400, 11401) and (11402, 11403) formed along folding lines (1149, 1148), respectively. As can be seen in FIG. 2a, when the box is folded to form a cubic volume, outer sides (1141, 1145) are folded to be perpendicular to the bottom plane (114), and interior sides (1142, 1146) are folded so that tabs (11420, 11421, 11460, 11461) engage with their respective openings (11400, 11401, 11402, 11403). Projections (116, 117) are simultaneously folded between exterior sides (1141, 1145) and inner sides (1142, 1146), respectively, when side (115) is positioned perpendicular to bottom plane (114) by folding along line (1151). In this manner, flaps (11410, 11450) are formed in exterior sides (1141, 1145), each providing elastic elements extending outward for snapping into flap holding means made up of the horizontal openings (104, 108) in interior sides (102, 106). Thus, by simply closing the lid over the bottom of the box, the flaps (11410, 11450) snap into the horizontal opening provided by notch (104), resulting in a locking connection therebetween. FIG. 2b is an exploded view of the locking system of the present invention. The locked position is obtained by sliding part of the flap (11410) along opposite lateral sides (1040, 1041) of flap holding means (104), providing guide means for the locking mechanism of the present invention. In this manner, the lower end of flap (11410) is urged into the horizontal opening of flap holding means (104) while the upper part of the flap (11410) rests against lateral sides (1040, 1041) of notch (104). The lower end of flap (11410) pushes against the thickness of the horizontal opening created by notch (104) to provide the flap holding means. To open the box, the user slides fingers or any appropriate object into hole (1010), pushing flap (11410) against inner surface (1142). The box can be provided with as many openings and snapping flap systems as desired. Further, in order to prevent the openings from being used to grip the box, which may result in pressure being applied to the flap and the box inadvertently being opened, holes (1010, 1050) can be eliminated and replaced by scored areas that must be broken before the box can be opened. In another embodiment of the present invention, projections (112, 113) can be made to be integral with the inside of inner side (102) or (106) such that the projections have shapes matching holding means (104, 108) and can contribute to the locking mechanism of the present invention. FIG. 4 represents a packing process in which the box of the present invention can be used advantageously with a type of cushion which was the subject of French Patent Application No. 88.00879 filed by Bull S.A., entitled "Packing Cushion, Container for Such a Cushion, and Packing Process Employing Such a Cushion." The packing process of the present invention utilizes a shock absorbing cushion in a continuous form, cut to the desired dimension for surrounding a product to be packaged. The cross section of the cushion has holding means defined by a channel (8a) perpendicular to the plane of the cushion length and is further provided with a plurality of parallel slits (8b, 8d) constituting pivoting means to facilitate folding thereof. This packaging cushion can be supplied by a supply roll (9), wherein the cushion is cut to length by a cutter (11, 12). Once the cushion has been brought above a predetermined area in which the packing box has been positioned, the product to be packaged is placed on the cushion and the cushion is then inserted into the packing box. Cutting lines (8b, 8d) define the dimensions of the cushion and allow sides (8f, 8e) of the cushion to fold and slide along the interior sides (1146, 1142) of the box. Product (15) and cushion (8) are placed into the package by gravity and a manipulating arm subsequently folds side (8g) onto the product in order to protect the top thereof. A second manipulating arm positions lid portion (100) over the bottom portion (114), simultaneously causing flaps (11410, 11450) to snap into their respective notches (104, 108), thereby allowing side (8g) of the cushion to be pressed into position on top of product (15) by lid portion (100). Other modifications within the understanding of the individual skilled in the art are also part of the spirit of the invention. In particular, the bottom and lid portions of the box may be independent. In this case, the fourth side of the lid portion will be symmetrical with respect to the folding line (1004) of side (111) and connecting side (110) will be replaced by projections symmetrical to projections (112, 113). Likewise, the fourth side of the bottom portion of the box may be symmetrical with respect to folding line (1100) of side (115) having flaps symmetrical to flaps (116, 117) replacing common side (110) since the bottom and lid portions will no longer be connected by a common side (110). Accordingly, it is understood that the disclosed invention is not to be limited by what has been particularly shown and described except as indicated by the present claims which follow.
A packing box with self-locking closure, the packing box comprising a bottom portion including a plane having at least three adjacent sides and a lid portion including a plane having at least three adjacent sides, wherein at least one of the sides of the bottom portion includes a flap provided with a support and further wherein at least one of the sides of the lid portion opposite the bottom portion provided with a flap is provided with a flap holding element which can be combined with a guide in order to ensure that the box is automatically prevented from opening without outside intervention when the lid portion is placed over the bottom portion of the box.
1
This application claims priority from U.S. Provisional Patent Application No. 61/617,335, filed on 29 Mar. 2012. BACKGROUND The invention relates generally to the field of photovoltaic (PV) solar power systems, and more specifically to circuits for protecting PV active bypass circuits from damage caused by electrical surges. FIG. 1 is a high level block diagram of a conventional PV solar power system 10 including a plurality of PV subsections 11 connected in series. Each PV subsection 11 comprises a plurality of PV cells that are serially connected between a positive terminal 12 and a negative terminal 13 . For example, a typical PV subsection includes twenty four PV cells, and produces about 12V between 12 and 13 in full sunlight. An inverter 15 converts the dc voltage to ac and has an output 16 for coupling to the electrical power grid. There is also usually a disconnect switch 17 for shutting down the system 10 . Since the PV subsections 11 are connected in series, the current is the same in each subsection. Therefore, when one subsection is shaded (e.g., by a tree branch, or chimney) it acts like a bottleneck, restricting current flow in the entire string. The unshaded PV subsections try to force current flow through the shaded subsection, resulting in the shaded subsection becoming reverse-biased. But a reverse-biased PV cell dissipates energy instead of producing energy, so the shaded subsection gets hot, and can even be permanently damaged. The well known remedy is to include bypass diodes 14 that allow current to flow around the shaded PV subsections, rather than through them. Thus, the bypass diodes 14 protect the PV subsections from damage due to reverse bias, and also avoid a serious reduction in system 10 efficiency when the string is partially shaded. A common problem in PV systems, such as 10 , is overheating in one or more of the bypass diodes 14 . One solution is to replace the conventional bypass diodes 14 with active bypass circuits. There are many examples of such active bypass circuits in the prior art such as: U.S. Patent Application Publication number 2010/0002349 (La Scala, et al), U.S. Pat. No. 7,898,114 (Schmidt, et al), U.S. Patent Application Publication number 2009/0014050 (Haaf), and U.S. Patent Application Publication number 2011/0006232 (Fahrenbruch, et al). FIG. 2 is a high level block diagram that is typical of such prior art, showing an active bypass circuit 20 comprising: a metal-oxide-semiconductor field-effect transistor (MOSFET) 22 with an integral body diode 21 , and a power-supply/control circuit 24 . When the PV subsection 11 is partially shaded, the string current initially flows through the MOSFET's body diode 21 , creating a voltage (V DS ) of approximately −500 mV from drain 12 to source 13 . The power-supply/control circuit 24 amplifies V DS , producing approximately 5V between the MOSFET's gate 23 and it's source 13 , thereby turning on the MOSFET 22 and reducing heat dissipation. When the PV subsection 11 is unshaded, the polarity of the drain-to-source voltage reverses, causing the power-supply/control circuit 24 to shut down and discharge the gate-to-source capacitance of the MOSFET 22 , thereby turning off the MOSFET 22 again. Another problem with conventional bypass diodes 14 is low reliability. For example, a 2012 report (Kato, et at) from Japan's Research Center for Photovoltaic Technologies (RCPVT) found that 47% of the 1272 solar power modules they examined, at a large PV installation called Mega-Solartown, had at least one failed bypass diode, after just eight years of service. And in 2010 an official report from the Solar American Board of Codes and Standards (www.solarabcs.org) stated “ . . . undetected bypass diode failures may be an endemic industry-wide sleeper problem . . . ”. And yet, the PV industry still knows little about the true extent or causes of these bypass diode failures. One of the main suspected causes is electrical surges, which may destroy the diodes outright, or just weaken them, making them more susceptible to thermal runaway. There are at least two types of surges that can happen in PV systems: an inrush surge when the cutoff switch 17 is closed; and lightning-induced surges. For example, FIG. 1 shows how a nearby lightning strike can induce current surges that damage or destroy bypass diodes 14 . There are many places in the world where lightning strikes are frequent, and a lightning rod 6 is often placed in close proximity to a solar power array to prevent the lightning 5 from striking the array directly. The lightning discharge current I DIS —which can easily exceed 40 kA—flows down the lightning rod 6 and into earth 8 via a ground wire 7 . An intense magnetic field is formed around the wire 7 . If the ground wire 7 comes close to a PV subsection 11 , as shown at the bottom of FIG. 1 , then some of the magnetic flux lines 9 can link the circuit loop consisting of the PV subsection 11 and the bypass diode 14 , causing an induced current I SURGE to flow through the bypass diode 14 . I SURGE can exceed 200 A at it's peak, and can flow in either direction. If I SURGE flows through the bypass diode 14 in the forward direction, there is only a small voltage drop across the diode, typically 2V or less. However, if I SURGE flows through the bypass diode 14 in the reverse direction, the diode 14 goes into avalanche breakdown, and the voltage across the diode 14 is typically about 50V. So, reverse current flow is the worst case by far, because the diode 14 absorbs much more energy. For example, assume the peak surge current is 200 A, and the avalanche voltage is 50V. Then the peak power in the diode 14 during the surge is (200 A)(50V)=10 kW. But the surge typically has an effective width of only about 20 μs, so the energy absorbed by the diode is roughly (20 μs)(10 kW)=200 mJ. The diode must absorb all the energy because the surge happens too quickly for heat to diffuse out through the diode's package, so heat-sinks are of no use in reducing the sudden spike in junction temperature. Consequently, the diode's junction temperature suddenly shoots up, as much as 70° C., possibly with catastrophic results. In fact, some Schottky diodes used for bypass in PV systems fail at only about 50 mJ avalanche energy. Active bypass circuits such as 20 can usually absorb more energy than traditional Schottky bypass diodes, but not much. For example, low-cost MOSFETs used in active bypass circuits for PV systems typically have avalanche energy ratings of about 75 mJ to 100 mJ. Therefore, there is a need in the solar power industry for a low-cost means of protecting MOSFETs in active bypass circuits against damage caused by electrical surges. SUMMARY The protection circuit disclosed herein turns on the MOSFET in a PV active bypass circuit at the beginning of a surge, and keeps it turned on until after the surge is ended. This greatly reduces the drain-to-source voltage during the surge, thereby greatly reducing the energy absorbed by the MOSFET. Other features and advantages of the present invention disclosed herein will become apparent from the following more detailed description, when taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings illustrate the invention. In such drawings: FIG. 1 is a high level block diagram of a conventional photovoltaic solar power system; FIG. 2 is a high level block diagram of a conventional active bypass circuit; FIG. 3 is a high level block diagram of an active bypass circuit with the protection circuit disclosed herein; FIG. 4 shows example waveforms to illustrate the operation of the protection circuit. FIG. 5 is a simplified schematic diagram of a first exemplary embodiment of the protection circuit; and FIG. 6 is a simplified schematic diagram of a second exemplary embodiment of the protection circuit. DETAILED DESCRIPTION FIG. 3 is a high level block diagram showing a subsection 11 of a PV array, with an active bypass circuit 20 that utilizes a power MOSFET 22 , and a protection circuit 30 as disclosed herein. The protection circuit 30 comprises: a switch 31 that couples the MOSFET's 22 drain to it's gate when closed; a diode 32 in series with the switch 31 ; a bistable circuit 33 for controlling the switch 31 ; and a detection circuit 34 for setting the bistable circuit 33 . FIG. 4 shows example waveforms to illustrate the operation of the protection circuit 30 and it's major advantages. The upper waveform is the surge current I SURGE , consistent with the 8 μs/20 μs waveform shape defined in the IEC 61000-4-5 standard, which is commonly used to simulate a lighting strike. The lower waveforms show the drain-to-source voltage (V DS ) across the MOSFET 22 and protection circuit 30 resulting from I SURGE . V 1 is the initial value of V DS before the surge begins. When the lightning strike occurs at night V 1 is nearly zero since there is only star light or street lamps shining on the PV subsection 11 . However, it is possible to have a lightning strike in the daytime, or some other kind of surge, such as an inrush surge when the cutoff switch 17 is closed. So V 1 could be as high as 12V. The dashed voltage waveform is typical of an active bypass circuit 20 without the protection circuit 30 . At the beginning of the surge, the MOSFET 22 , begins to avalanche. V DS goes above the MOSFET's reverse breakdown voltage (V BR ) and stays there for the entire duration of the surge. The solid voltage waveform is typical of the an active bypass circuit 20 with the protection circuit 30 disclosed herein. Once again, V DS shoots up at the beginning of the surge. But when V DS exceeds a first predetermined threshold (V TRIG ) the detection circuit 34 sets the bistable circuit 33 and closes the switch 31 , thereby connecting the MOSFET's drain 12 to it's gate 23 via the diode 32 . Thus, most of V DS is applied between the gate and source, thereby turning on the MOSFET 22 . So the MOSFET 22 quickly pulls V DS down to V 2 , which is typically 4V to 6V depending on the characteristics of the MOSFET and the magnitude of the surge current. V 2 is below V TRIG so the detection circuit 34 no longer asserts the switch's control signal 35 , but the bistable circuit 33 keeps 35 asserted so the switch 31 stays closed. The bistable circuit 33 keeps the switch 31 closed until it is reset in response to V DS falling below a second predefined threshold (V RST ). For example, after the peak, the current through the MOSFET 22 drops off rapidly, but the diode 31 acts like a peak detector, blocking the discharge of the MOSFET's 22 gate-to-source capacitance. If there is sunlight, the PV subsection 11 will try to keep V DS above about 10V, but a typical PV subsection 11 has a short-circuit current of less than 10 A, while the gate-to-source voltage of 22 is still large enough to sink I PEAK . So the MOSFET 22 is able to pull V DS down to less than 100 mV typically, which is well below V RST . Thus, the power MOSFET 22 , it's gate-to-source capacitance, and the diode 32 constitute a means for resetting the bistable circuit 33 in response to the drain-to-source voltage being relatively lesser than the second predefined voltage threshold, V RST . The affect the protection circuit 30 has, of reducing V DS during the surge, reduces the energy absorbed by the MOSFET 22 , typically by up to 80% compared to the unprotected MOSFET represented by the dashed curve in FIG. 4 . Two exemplary embodiments of the protection circuit 30 will now be shown in more detail. FIG. 5 shows a simplified schematic of a first exemplary embodiment of the protection circuit 30 wherein: items 54 - 56 constitute the detection circuit 34 ; items 26 , 50 , 51 , and 57 constitute the bistable circuit 33 ; and items 50 - 53 also constitute the switch 31 . In this first exemplary embodiment, V TRIG is the trigger transistor's 54 threshold voltage V T , scaled-up by the resistive divider 55 and 56 . For example, assume resistors 55 and 56 are 500 kΩ and 6.5MΩ respectively, and the V T of 54 is 1.3V; then V TRIG =1.3(1+6.5/0.5)=18.2V. V TRIG is normally chosen to be in the 17V to 25V range for two reasons. First, to avoid false triggers V TRIG must be well above the maximum dc output voltage that the PV subsection 11 can produce in full sunlight, which is typically about 12V. And second, V TRIG must be well below the avalanche voltage of the MOSFET 22 , which is typically 30V; otherwise, the MOSFET 22 could prevent the protection circuit 30 from triggering. MOSFETs with higher avalanche voltage are undesirable because they generally have higher on-resistance compared to 30V MOSFETs in the same price range. The two bipolar transistors 50 and 51 form a Silicon Controlled Rectifier (SCR) which is a common type of thyristor, often used in integrated circuits for ESD protection. When the trigger transistor 54 is turned on, current flows into the base of the NPN transistor 50 ; this causes current to be pulled from the base of the PNP transistor 51 , which then dumps more current into the base of the NPN 50 , making a positive feedback loop that quickly saturates both 50 and 51 . Emitter resistors 52 and 53 are often included in SCRs to avoid premature triggering due to leakage currents. Once triggered by the detection circuit 54 - 56 , the SCR stays in this saturated state after the trigger transistor 54 is turned off, until the current through the SCR drops below a critical threshold, and then it turns off. The load resistor 57 provides enough current flow through the diode 26 , typically at least a few microamps, to keep the SCR from turning off until V IN falls below V RST at the end of the surge event. V RST is approximately the sum of the MOSFET's 22 gate-to-source voltage after the peak of the surge current, the diode 26 forward drop, and the collector-to-emitter saturation voltages of the bipolar transistors 50 and 51 . FIG. 6 shows a simplified schematic of a second exemplary embodiment of the protection circuit 30 wherein: items 60 - 62 constitute the detection circuit 34 ; items 63 - 66 constitute the bistable circuit 33 ; and the P-channel MOSFET 71 constitutes the switch 31 . Additionally, items 67 - 70 form a reset circuit for resetting the bistable circuit 33 at power-up. The bistable circuit 63 - 66 is a set/reset flip-flop comprising two cross-coupled N-channel FETs 65 - 66 and two pull-up resistors 63 - 64 . One of ordinary skill in the art will understand that there are many other well known flip-flop circuit topologies that could be used alternatively, such as: cross-coupled P-channel FETs, cross-coupled bipolar transistors, cross-coupled NAND gates, or cross-coupled NOR gates. Additionally, one of ordinary skill in the art will know that the switch 71 could also be implemented using a bipolar transistor, or even a junction field-effect transistor (JFET). In the reset circuit, 69 has a threshold voltage that is relatively less than the threshold of 70 . At start-up, as V DS increases from zero, 69 turns on first, thereby initializing the state of the bistable circuit 63 - 66 . As V DS increases further 70 turns on, which turns 69 off, thereby enabling the bistable circuit 63 - 66 to be set by the detection circuit 60 - 62 in the event of a surge. Also, V RST is approximately equal to the threshold voltage of 70. The detection circuit 60 - 62 in this second exemplary embodiment operates similarly to the detection circuit 54 - 56 from the first exemplary embodiment, only the trigger transistor 62 is N-channel instead of P-channel. Although several embodiments have been described in detail for purposes of illustration, various modifications may be made to each without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
A protection circuit for metal-oxide-semiconductor field-effect transistors (MOSFETs) that are used as active bypass diodes in photovoltaic solar power systems is disclosed. The protection circuit comprises, a detection circuit for detecting the start of a surge event, a switch disposed to connect the MOSFET's drain to it's gate in response to the start of the surge, a diode in series with the switch, a bistable circuit for keeping the switch closed during the surge, and a means of resetting the bistable circuit after the surge.
8
CROSS REFERENCE TO RELATED APPLICATIONS None. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manually operated dispenser for medicated or non-medicated orally dissolving strips provided in roll form. The dispenser cuts portions of the roll to a predetermined size in the manner of the strips currently available in single sheets and housed in the vial shown in patent Des. 423,302. The dispenser includes spring-loaded structure rotating the roll and presenting material of a predetermined strip length to a cutting blade, then slicing the strip from the roll. 2. Description of the Related Art Haner, et al. Des. 423,302 is the vial housing the strips currently on the market. Wise, Re. 22,827, is one of many patents showing a stripping finger used to contact a rotatable cylinder to remove paper from the cylinder. Carriero, U.S. Pat. No. 3,598,395, automatically feeds cards from a stack of cards by the use of detents 12–15. Van Der Does, U.S. Pat. No. 3,627,307, dispenses film from a stack one sheet at a time by clipping the top sheet of the stack after the top sheet is raised by pinching the stack. Stephens, et al, U.S. Pat. No. 4,269,403 show a feed roller with a plurality of fingers thereon. Pressure by the fingers on the stack is variable. Wade, et al., U.S. Pat. No. 5,881,350 represents a number of structures using two feed rollers one on the top and the other on the bottom of a stack. Simpson, U.S. Pat. No. 6,550,636 dispenses single sheet from a spring-loaded structure having no moving parts. SUMMARY OF THE INVENTION This invention relates to a dispenser for the orally dissolving strips currently marketed under the trademark POCKETPAKS, for example. The strips, which may be medicated or non-medicated, are packaged and sold in a vial shown in DES. 423,302. The strips rapidly dissolve in the mouth thereby acting as an oral delivery system for drugs, breath freshener, etc. The present invention uses a roll of such strip material and cuts portions of the roll to a desired length. The roll is formed of the strip material plus a base layer serving as a carrier and as a separator. The base layer/separator has at least one apertured edge formed thereon for engaging an advancing mechanism, and delivering a portion of the strip material to a separating and cutting location. The base layer minimizes the adverse effects of temperature and humidity on the strip material by preventing portions of the strip material from contacting other portions of the strip material. For example, the aforesaid POCKETPAKS vial is marked for storage between 59° F.–77° F. and to avoid humidity. Temperature and humidity cause the strip material to become too brittle or too soft or permits them to stick together. A principal object of the invention is to provide a dispenser for a roll of medicinal strip material. Another object of the invention is the provision of a dispenser, which separates the medicinal material from a carrier/separator and cutting the medicinal material to a desired length. A further object is the provision of dispenser of the class described having a base and a spring-loaded removable cover forming a storage space for a roll of medicinal material. A still further object and advantage of the invention is the incorporation of a cutting blade on the spring-loaded cover for cutting the medicinal material to a desired length. Another object and advantage of the invention is the provision of a rack and pinion structure for advancing a portion of the medicinal material from the roll to a carrier separating and cutting station. Another object of the invention is the provision of a dispenser where the roll of material is mounted within a carrier. The foregoing, as well as further objects and advantages of the invention will become apparent to those skilled in the art from a review of the following detailed description of my invention, reference being made to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the preferred embodiment of our invention; FIG. 2 is an exploded view of the preferred embodiment of our invention; FIG. 3 is an exploded view of the preferred embodiment of our invention, partially assembled; FIG. 4 , is a sectional view of the preferred embodiment of our invention; FIGS. 5A–5B , are sectional views of the preferred embodiment of our invention, in a first and a second position. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Like reference numerals have been used to designate like parts in FIGS. 1–5A and 5 B. FIG. 1 is a perspective view of the dispenser of our invention. A circular base portion 6 has a tray 4 formed therein. The tray 4 is positioned beneath a cutting housing 8 . A spring loaded manually depressed top portion 2 is attached to the base 6 . FIG. 2 , is an exploded view of the dispenser of FIG. 1 . A roll 26 of medicinal strip material is formed by carrier 17 which has notches 28 and 30 formed along both edges and orally dissolving strip material 25 peelably affixed to the carrier. Roll 26 is inserted into circular roll support 34 . The support 34 has a feed slot 36 formed therein for receiving a portion of the roll 26 and permitting the portion to extend along the surface of the support 34 so that teeth 38 formed on the surface of support 34 thereon can engage notches 28 and 30 . The support 34 has an enlarged end cap portion 32 , which has gear teeth 15 formed along a portion of the surface thereof. A cutting blade 10 is affixed to top portion 2 . This cutting blade is guided within the aperture 12 in the pocket housing 8 both formed in the circular base 6 . The support 34 and the roll 26 mounted therein are in turn supported in a housing 18 . The housing 18 has an inclined floating keeper arm 20 formed interiorly thereof for maintaining tension on the roll 26 while a portion of the roll 26 is conveyed to the cutting blade housing 8 . Circular spring supports 14 and 16 are also formed in housing 18 . Notches 22 , 24 are formed in the sidewalls of the housing 18 to support roller rod 39 on the housing 18 . Roller rod 39 is inserted into the hollow center of the roll 26 through hole 36 ′ in the end cap 32 of roller support 34 . The notches 22 , 24 and the diameter of the roller rod 39 are dimensioned such that the roll 26 will always ride in the aperture formed in inclined keeper arm 20 . As the diameter of roll 26 decreases by use of the material, the rod drops down in the notches 22 , 24 . FIG. 3 is an exploded view of the apparatus of FIG. 2 showing more detail. In FIG. 3 , a portion of the roll 26 is shown extending onto the surface of the support 34 with notches 28 engaging teeth 38 (not shown). Springs 3 and 5 are mounted in spring supports 16 and 14 , respectively. These springs fit onto rods 7 and 9 formed in the top portion 2 . As will now be seen, gear teeth 15 are part of a rack and pinion arrangement with gear 13 removeably attached to support portion 11 formed in top 2 . Further detail of the mounting of cutting blade 10 can also be seen in FIG. 3 . The blade 10 is fit into a blade support pocket 1 . The blade support is a compression fitting removeably supporting the blade 10 in a pocket formed between the two walls of blade support 1 . FIG. 4 shows the parts of FIG. 3 assembled in its resting position. FIGS. 5A–5B are sectional views of the apparatus of FIG. 4 with FIG. 5B showing the top 2 fully depressed. When top 2 is depressed, the rack and pinion gear assembly 13 , 15 causes support 34 to rotate a predetermined distance thereby causing a length of material from roll 26 to be fed to a location where its carrier portion 17 and medicinal material portion 25 are separated, then the material 25 is cut. Separation is accomplished by peeling the carrier 17 from the medicinal portion 25 . The peeling occurs via the finger hook 23 guiding the tounged portion of carrier 17 downwardly while film portion 25 is guided via shield 19 into trough 4 . The teeth 21 hold the carrier preventing it from rolling back when the top portion is returned to its uppermost position. The surface 19 causes the material 25 to be directed into hopper 4 while carrier 17 is directed downwardly into the hollow storage area 27 in the circular base 6 . The medicinal material portion 25 is not so captured but is peeled off the carrier by the hook 23 onto the hopper 4 for cutting by blade 10 . In order for the strip portion 25 is dispensed into the hopper 4 , it must be separated from the carrier 17 . In order to start the required peeling action, the roll is formed with an extension or tongue at its leading edge that is manually fed into the hopper 27 until the edge of the strip portion reaches the hook separator 23 . Separation or peeling will then be effected by the roll advance motion created by the rack and pinion mechanism. Teeth 21 cooperate with keeper arm 20 to form a floating keeper arrangement to insure that the roll does not retract with support drum 34 when the drum returns to set up for the next cutting cycle of metered advancement. This floating keeper maintains tension on the roll 26 because a portion of the roll rides on the arm and is held by teeth 21 . Further modifications to the apparatus of the invention may be made without departing from the spirit and scope of the invention; accordingly, what is sought to be protected is set forth in the appended claims.
A manually operated dispenser for medicated or non-medicated orally dissolving strips provided in roll form cuts portions of the roll to a predetermined size in the manner of the strips currently available in single sheets and housed in the vial shown in patent Des. 423,302. The dispenser includes spring-loaded structure rotating the roll and presenting material of a predetermined strip length to a cutting blade, then slicing the strip from the roll.
1
FIELD OF THE INVENTION The present invention relates to the synthesis of cytotoxic anti-tumor antibiotics such as CC-1065 and analogs thereof. In particular, the present invention provides an improved synthesis for seco(−)CBI (5-hydroxy-3-amino-1-[S]-(chloromethyl)-1,2-dihydro-3H-benz(e)indole), and for the synthesis therefrom of CC-1065 analogs comprising a cyclopropabenzindole (CBI) alkylating moiety, which may be incorporated into cell-targeted therapeutic agents. BACKGROUND CC-1065 is a highly cytotoxic anti-tumor antibiotic isolated from cultures of Streptomyces zelensis. The CC-1065 molecule consists of three substituted pyrroloindole subunits linked by amide bonds. The “A” subunit is the alkylating cyclopropapyrroloindole (CPI) moiety, while the “B” and “C” subunits are identical pyrroloindole moieties. Novel cytotoxic agent-cell binding agent conjugates comprising a cell-binding, agent chemically linked to analogs of CC-1065 have been described [U.S. Pat. Nos. 5,475,092; 5,585,499; 5,846,545, R. V. J. Chari et al., Cancer Res., 55, 4079-4084 (1995)]. These cytotoxic agent-cell binding agent conjugates have therapeutic use because they deliver the cylotoxic agent to a specific cell population in a targeted fashion. In these cytotoxic agents, herein called DC1 and its derivatives, the alkylating CPI subunit “A” was replaced by the benzannelated analog cyclopropabenzindole (CBI). CBI is the precursor required for the synthesis of DC1 drugs and its derivatives. The original synthesis of CBI was described by D. L. Boger et al., [ J. Org. Chem., 55, 5823-5833 (1990)]. An “improved” synthesis, also described by D. L. Boger et al., [ J. Org. Chem., 57, 2873-2876 (1992)] is a 15-step process starting from naphthalene diol. Other pathways for the syntheses of CBI from different starting materials have also been described [K. J. Drost & M. P. Cava, J. Org. Chem., 56, 2240-2244 (1991), P. A. Aristoff & P. D. Johnson, J Org. Chem., 57, 6234-6239 (1992)]. These syntheses are lengthy, time-consuming, expensive and provide poor yields. A key step in the synthesis of CBI is the resolution of the enantiomers at the seco-CBI stage. Only the seco(−)enantiomer is biologically active, and it is important to efficiently remove the inactive (+) isomer. Isomer separation can be achieved, for example, by chiral HPLC. This method is not very efficient when applied to seco-CBI because the separation between the two enantiomers is poor. In addition, even the optimized separation on a chiral column is poor (retention time difference between the two isomers is less than 5 minutes), and requires a very non-polar solvent system, such as a mixture of 95% hexane and 5% isopropanol (Boger et al., 116, J.Am. Chem Soc., 7996-8006 (1994). Under these conditions, seco-CBI is poorly soluble, resulting in low efficiency (small loading amounts) on the column, and thus, long processing times. Alternatively, the enantiomeric mixture can be converted into a set of diastereomers by esterification with a chiral acid, such as mandelic acid, followed by separation by HPLC. However, the separated ester has to be hydrolyzed and then repurified, thus adding an extra processing step. The therapeutic utility and promise of drugs such as DC1 and its derivatives, for example in the treatment of various cancers, makes it desirable that improved synthetic methods be developed in order to be able to manufacture CBI in large scale, by a simple, easily scalable, high-yield, inexpensive process that uses inexpensive and easily available starting materials. The present invention provides such an improved synthetic method that addresses the aforementioned shortcomings of the prior art. All these advantages and more are provided by the invention described herein, as will be apparent to one of skill in the art upon reading the following disclosure and examples. SUMMARY OF THE INVENTION The inventors have discovered a new, economical and efficient synthesis for seco(−)CBI that can utilize, for example, the commercially available and inexpensive compound 1,3-dihydroxynaphthalene as a starting material, and which can be accomplished in as few as seven steps. The inventors have further provided related flexible and efficient syntheses for the conversion of seco(−)CBI into a wide variety of DC1 drugs. While there are several differences between the synthetic scheme for seco(−)CBI described herein and any previously reported method, one exemplary difference is the use of the same protecting group for the amino and the hydroxy groups of the key precursor, 4-hydroxy-2-naphthyl amine. Thus, in one embodiment of the method described herein, a di-tert.-butyloxycarbonyl (di-t-boc) protected compound is used, instead of a separate benzyl protecting group for the hydroxyl group and a tert.-butyloxycarbonyl (t-boc) protecting group for the amine function, described previously. Thus, in the present syntheses, some of the redundant protection and deprotection steps have been removed. These and other changes have shortened the synthesis time, improved the product yield considerably, and also improved the separation of enantiomers. In the present invention, the use of two t-boc protecting groups is preferred and gives a seco-CBI enantiomeric mixture that separates well on a chiral HPLC column. In addition, the column can be run with a solvent mixture with a higher polarity, for example containing 20% isopropanol, in which the compound has good solubility. These two features greatly increase the loading capacity of the column and therefore the efficiency of the separation process, and thus decrease the processing time considerably. Thus, in a first aspect, the present invention provides a process for preparing the seco(−)CBI of formula (I): in which a di-protected compound of formula (II) is used, in which R is a protecting group such that the amino group and hydroxyl group are protected by the same compound: and the compound of formula (II) is converted by alkylation and ring-closure reactions to provide a racemic mixture represented by a compound of formula (III): The (−) isomer of racemate (III) can be isolated, for example by chiral chromatography, and the isolated (−) isomer of the compound of formula (III) is deprotected to produce the compound of formula (I). In preferred embodiments, R is tert-butyloxycarbonyl and the alkylation step employs 1,3-dichloropropene. In certain embodiments, a compound of formula (II) can be conveniently prepared from an inexpensive and easily obtained starting material such as 1,3-dihydroxynapthalene by amination and protection of the hydroxyl and amine groups (FIG. 1 ). In a second aspect, the present invention provides a process for preparing DC1 by reacting the amino group of a compound of the seco(−)CBI of formula (I) to form a peptide bond, where the seco(−)CBI may be prepared according to the method of the present invention. Thus, in a first embodiment of this second aspect of the invention, a peptide bond is formed by reacting the amino group of seco(−)CBI with the carboxyl group of, for example, a compound of formula (IV) under suitable conditions, in which R 1 represents, in this embodiment, an alkyl or aryl thio group that forms a disulfide bond within a compound of formula (IV), such as, for example, an alkyl or aryl thiol, or, more specifically, —S—CH 3 or —S-pyridyl. Such disulfides can be used to link the DC1 compound to, for example, a cell-targeting agent via a bond that can be cleaved inside the target cell. This embodiment is not limited to only the synthesis of the DC1 compound corresponding to the product of the reaction using compound (IV), but can also be readily adapted to produce a wide variety of DC1 compounds, including those in which the group that is capable of bonding to a cell-targeting agent can be other than a thio or disulfide group, such as, for example, an acid-labile group, a photo-labile group, a peptidase-labile group, or an esterase-labile group, depending upon the analog of compound (IV) that is selected. In a further embodiment of this aspect of the invention, it is not required that the coupling of seco(−)CBI occurs as a terminal step of the synthesis. Thus, in this embodiment the DC1 compound is synthesized from a bis-indolyl moiety, a disulfide-containing moiety, and seco(−)CBI, by their attachment via peptide bonds, and the order in which these three components of DC1 are assembled is not critical. For example, the bis-indolyl moiety and seco(−)CBI can be linked prior to the attachment of the disulfide-containing moiety. BRIEF DESCRIPTION OF THE FIGURES FIG. 1 illustrates a synthesis of seco(−)CBI (5-hydroxy-3-amino-1-[S]-(chloromethyl)-1,2-dihydro-3H-benz(e)indole) according to the method of the present invention. FIG. 2 illustrates an exemplary synthesis (path A) of DC1 according to the method of the present invention, FIG. 2 illustrates an exemplary synthesis (path A) of DC1 according to the method of the present invention. FIG. 3 illustrates a second exemplary synthesis (path B) of DC1 according to the method of the present invention. DETAILED DESCRIPTION The present invention provides an improved synthesis of seco(−)CBI (5-hydroxy-3-amino-1-[S]-(chloromethyl)-1,2-dihydro-3H-benz(e)indole) (7), and also improved syntheses of DC1 and its derivative compounds that use seco(−)CBI as a reagent. Optionally, the synthesis of seco(−)CBI can utilize 1,3-dihydroxynapthalene as a starting material, which is inexpensive and readily available. The present invention also provides novel compounds of formula (II): wherein R is a protecting group as defined herein. The term “DC1 and its derivatives” as used herein refers to CC-1065 analogs having, as their alkylating subunit “A,” a cyclopropabenzidole (CBI) subunit in its open chloromethyl form in place of the cyclopropapyrroloindole (CPI) unit of CC-1065. DC1 compounds further comprise “B” and “C” subunits that are indole units or analogs thereof. The “B” and “C” subunits are linked by an amide bond, and provide carboxyl and amnino functional groups for attachment via amide bonds to the “A” subunit and a disulfide-containing moiety, respectively. Thus the “B” and “C” subunits are not particularly limited, and can be, for example, any of the compounds of formulae (V)-(XII), or related compounds disclosed in U.S. Pat. Nos. 5,585,499; 5,475,092, and 5,846,545. Thus, the “B” and “C” subunits of DC1 can include 2-carboxy-indole or 2-carboxy-benzofuran derivatives, or both, as represented by the compounds of formulae (V)-(XII). As may be ascertained from the natural CC-1065 and from the properties of the analogs that have been published (e.g. Warpehosld et al, 31 J. Med. Chem. 590-603 (1988), Boger at al, 66 J. Org. Chem. 6654-6661 (2001)), the “B” and “C” subunits can also carry different substituents at different positions on the indole or benzofuran rings, corresponding to positions R 1 -R 6 of formulae (V)-(XII), and retain potent cytotoxic activity. Within formulae (V)-(XII), R 1 to R 6 , which may be the same or different, independently represent hydrogen, C 1 -C 3 linear alkyl, methoxy, hydroxyl, primary amino, secondary amino, tertiary amino, or amido. Examples of primary amino group-containing substituents are methyl amino, ethyl amino, and isopropyl amino. Examples of secondary amino group-containing substituents are dimethyl amino, diethyl amino, and ethyl-propyl amino. Examples of tertiary amino group-containing substituents are trimethyl amino, triethyl amino, and ethyl-isopropyl-methyl amino. Examples of amido groups include N-methyl-acetamido, N-methyl-propionamido, N-acetamido, and N-propionamido. Within formulae (V)-(XII), R″ represents an amine or substituted or unsubstituted C 1 -C 20 alkyl amine that is capable of forming an amide bond to a carboxyl of the disulfide-containing moiety of DC1. The preferred embodiment of R″ is —NH 2 . The disulfide-containing moiety that is used in the synthesis of DC1 is of the structure HOOC—R 7 —S—R 8 , wherein R 7 represents a linker region that is not particularly limited and can be, for example, a substituted or unsubstituted C 1 -C 20 alkyl group, a polyethylene glycol spacer, and the like. Thus, R 7 can represent methyl, linear alkyl, branched alkyl, cyclic alkyl, simple or substituted aryl or heterocyclic or a polyethylene glycol chain. Examples of linear alkyls represented by R 7 include methyl, ethyl, propyl, butyl, pentyl and hexyl. Examples of branched alkyls represented by R 7 include isopropyl, isobutyl, sec.-butyl, tert.-butyl, isopentyl and 1-ethyl-propyl. Examples of cyclic alkyls represented by R 7 include cyclopropyl, cyclobutyl, cyclopentyl and cyclohexyl. Examples of simple aryls represented by R 7 include phenyl and naphthyl. Examples of substituted aryls represented by R 7 include aryls such as phenyl or naphthyl substituted with alkyl groups, with halogens, such as Cl, Br, F, nitro groups, amino groups, sulfonic acid groups, carboxylic acid groups, hydroxy groups and alkoxy groups. Heterocyclics represented by R 7 are compounds wherein the heteroatoms are selected from O, N, and S, and examples include furyl, pyrrollyl, pyridyl, (e.g., a 2-substituted pyrimidine group) and thiophene. R 8 represents any suitable thiol leaving group that is capable of undergoing a disulfide exchange reaction whereby DC1 can be attached, for example, to a cell specific reagent such as an antibody or any of the cell binding agents disclosed in U.S. Pat. No. 5,475,092. Preferred embodiments of R 8 include —SCH 3 and thiopyridyl. Other examples include -Salkyl, -Saryl, glutathione, cysteine and the like. The term “protecting group” (R) as used herein represents any group that is capable of protecting the amino or phenolic hydroxyl group to which it is attached from further reaction and which is further capable of controlled subsequent removal, for example by treatment with an acid or base. Thus, amino-protecting groups stable to base treatment are selectively removed with acid treatment, and vice versa, and can be used to protect the amino group in the synthesis of seco(−)CBI herein. Examples of such groups are the FMOC (E. Atherton and R. C. Sheppard in The Peptides, S. Udenfriend, J. Meienhofer, Eds., Academic Press, Orlando, 1987, volume 9, p.1), and various substituted sulfonylethyl carbamates exemplified by the Nsc group (Samukov et al., Tetrahedron Lett, 1994, 35:7821; Verhart and Tesser, Rec. Trav. Chimr Pays-Bas, 1987, 107:621). Additional amino-protecting groups include but are not limited to, carbamate-protecting groups, such as 2-trimethylsilylethoxycarbonyl (Teoc), 1-methyl-1-(4-biphenylyl)ethoxycarbonyl (Bpoc), t-butoxycarbonyl (BOC), allyloxycarbonyl (Alloc), 9-fluorenylmethyloxycarbonyl (Fmoc), diphenyloxycarbonyl, 2,2,2-trichloroethyl oxycarbonyl, diisopropylmethyl oxycarbonyl, 1-adamantyl oxycarbonyl, vinyl oxycarbonyl, methoxy benzyl oxycarbonyl, nitrobenzyl oxycarbonyl, cyclohexyl oxycarbonyl, cyclopentyl oxycarbonyl, and benzyloxycarbonyl (Cbz); amide-protecting groups, such as formyl, acetyl, trihaloacetyl, benzoyl, and nitrophenylacetyl; sulfonamide-protecting groups, such as 2-nitrobenzenesulfonyl; and imine- and cyclic imide-protecting groups, such as phthalimido and dithiasuccinoyl. Those skilled in the art are familiar with such equivalent amino-protecting groups. As an example, which is not intended to be limiting, amino protecting groups such as 2,6dinitrohenzenesulfonyl, 4-nitrobenzenesulfonyl or 2,4nitrobenzenesulfonyl groups may be used. Alternatively, another amino protecting group may be used instead of a sulfonyl protecting group. In the present invention, tert-butoxycarbonyl (BOC) is preferred. The formation of the amide bonds in the synthesis of seco(−)CBI and DC1 can be catalyzed by a variety of agents known to those of skill in the art. For example, carbodiimides are used to mediate the formation of a peptide bond between a carboxylate and an amine, and water soluble and insoluble species of carbodimide can be selected as appropriate. EDC (1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride) is preferred. Other examples of amide coupling reagents useful in the present invention include EDC together with sulfo-NHS, CMC (1-cyclohexyl-3-(2-morpholinoethyl) carbodiimide), DCC (dicyclohexyl carbodiimide), DIC (diisopropyl carbodiimide), Woodward's reagent K, N,N′-carbonyldiimidazole, PyBOP (benzotriazole-1-yl-oxy-tris-pyrrolidinophosphonium heaxflurophosphate), TBTU (2-(1H-Benzotriazole-1-yl)-1,1,3,3-trtramethyluronium tetrafluoroborate), HBTU (2-(1H-Benzotriazole-1-yl)-1,1,3,3-trtramethyluronium hexafluorophosphate), BOP (Benzotriazole-1-yl-oxy-tris-(dimethylamino)-phosphonium hexafluorophosphate), PyBrOP (Bromo-tris-pyrrolidino-phosphonium hexafluorophosphate), and the like. The isolation of the (−) enantionmer of the diprotected seco(−)CBI precursor, a compound of formula (III), is an important step in the synthesis of seco(−)CBI. Isolation of the (−) enantiomer can be carried out by any method known to those of skill in the art for the separation of enantiomers. For example, the use of a chiral matrix and liquid chromatography is preferred. Most preferably, HPLC over a chiral column is used. It is a benefit of the present invention that the separation of the (−) enantiomer is performed upon the di-protected precursor rather than upon seco(−)CBI (7), as described above. Suitable chiral matrices include, for example, Chiralpak AD column (Diacel), Chiralcel OD, Chiralcel OJ, and the like. The term “suitable conditions,” as applied herein to specific aspects of the synthesis of seco(−)CBI and DC1, such as in reference to alkylation or ring-closure reactions, represents both the specific methods disclosed in the Examples herein and those equivalent methods, suitably adapted to the specific DC1 species that is to be synthesized, known to those of skill in the art. The synthesis of DC1 requires the coupling, via amide bonds, of seco(−)CBI, a “B” and “C” subunit, and a disulfide-containing moiety. The order in which these components are coupled is not critical and the synthesis can be easily adapted such that the couplings occur in any order. Thus, seco(−)CBI and the “B” and “C” subunits can be first coupled and then the disulfide-containing moiety can be attached, or the disulfide-containing moiety and the “B” and “C” subunits can be first coupled and then the seco(−)CBI can be attached. Both processes are illustrated in the Examples herein. It is further within the scope of the present invention that the “B” and “C” subunits need not be first coupled via an amide bond in the synthesis of DC1 according to the present invention. Thus, it is within the scope of the present invention that, for example, seco(−)CBI and the “B” subunit are coupled, then the “C” subunit and the disulfide-containing moiety are coupled, and then DC1 is synthesized by coupling through the “B” and “C” subunits. Because DC1 comprises a linear sequence of 4 parts, it will be apparent that many permutations of the synthesis of DC1 according to the present invention are readily attainable. EXAMPLES The invention will now be illustrated by reference to certain non-limiting examples. Unless otherwise stated, all percentages, ratios, parts, and the like, are by weight. A summary of the exemplary syntheses (FIGS. 1-3) is followed by a detailed description of each step. The improved synthesis of CBI exemplified herein (FIG. 1) starts with 1,3-dihydroxy-naphthalene (1). Amination by treatment with ammonia at 125 to 140° C. in a pressure vessel provided 4-hydroxy-2-napthylamine 2, which was then converted to the di-t-boc compound 3 by treatment with di-tert-butyldicarbonate. lodination with N-iodosuccinimide proceeded in 86% yield to produce 4, which was alkylated to give compound 5 in 93% yield. Ring closure of 5 using tri-butyltin hydride in the presence of 2,2′-azobisisobutyronitrile (AIBN) proceeds smoothly in 94% yield to give the racemic di-t-boc-seco-CBI 6 in 94% yield. Separation of the racemic mixture is readily performed using a chiral HPLC column eluting with 20% isopropanol in hexane, where the retention times of the two isomers differ by 17 minutes, to give the desired di-t-boc-seco (−) CBI isomer 6b. Deprotection with hydrochloric acid provided seco(−)CBI, 7. Two independent synthetic routes for the conversion of seco-CBI 7 to DC1-SMe 16a are exemplified and are designated Path A (FIG. 2) and Path B (FIG. 3 ). In Path A (FIG. 2 ), the bis-indolyl moiety bearing a disulfide-containing substituent was synthesized, and then coupled in the final step to seco-CBI. In Path B, the bis-indolyl moiety was linked to seco-CBI, and the disulfide containing substituent was introduced in the final step (FIG. 3 ). In Path A, ethyl 5-nitroindole-2-carboxylate (8), which is commercially available, was hydrolyzed to the acid 9, which was then converted into the tert-butyl ester 10. Catalytic reduction of 10 with hydrogen provided the amino ester 11 in quantitative yield. Coupling of 11 with 5-nitroindole-2-carboxylic acid (9) in the presence of O-(benzotriazole-1-yl)-N,N,N′,N′-tetramethyluronium tetraflouroborate (TBTU) provided the nitro-bis-indolyl ester 12 in 89% yield. Reduction of the nitro group by catalytic hydrogenation, followed by coupling of the resulting amino compound 13 with 3-(methyldithio)propanoic acid provided 14a. The ester group in 14a was hydrolyzed with trifluoroacetic acid to give carboxylic acid 15a. Coupling of 15a with seco-CBI, in the presence of EDC provided DC1-SMe (16a). Reduction of DC1SMe with dithiothreitol provided DC1 (17). In Path B, 5-nitroindole-2-carboxylic acid 9 was first condensed with ethyl 5-aminoindole-2-carboxylate 18 to provide the bis-indolyl ester 19. Alkaline hydrolysis of 19, followed by coupling with seco-CBI provided the bis indolyl-seco-CBI compound 21. Reduction of the nitro group in 21 with hydrogen over Pd/C provided the amino-bis-indolyl-seco-CBI compound 22. Coupling of 22 with 3-(methyldithio)propanoic acid provided DC1-SMe 16a. Materials and Methods Melting points were measured using an Electrothermal apparatus and are uncorrected. NMR spectra were recorded on a Bruker AVANCE400 (400 MHz) spectrometer. Chemical shifts are reported in ppm relative to TMS as an internal standard. Mass spectra were obtained using a Bruker Esquire 3000 system. Ultraviolet spectra were recorded on a Hitachi U1200 spectrophotometer. Analytical HPLC was performed using a Beckman Coulter GOLD 125 system equipped with a Beckman Coulter system GOLD 168 variable wavelength detector and a Chiralcel OD 4.6×250 mm column. Preparative HPLC was performed on a R & S Technology Zonator system equipped with a Hitachi UV detector, using a self-packed Chiralcel OD 7.5×50 cm column. Thin layer chromatography was performed on Analtech GF silica gel TLC plates. Silica gel for flash column chromatography was from Baker. All solvents used were reagent grade or HPLC grade. Examples 1-5 Synthesis of seco(−)CBI (5-hydroxy-3-amino-1-[S]-(chloromethyl)-1,2-dihydro-3H-benz(e)indole)according to the scheme of FIG. 1 Example 1 Preparation of N-(tert-butyloxycarbonyl)-4-O-(tert-butyloxycarbonyl)-2-naphthylamine (3) A solution of 1,3-dihydroxynaphthalene (1, 50 g, 0.312 mol) in liquid ammonia (200 mL) at −78° C. was sealed in a 1 L steel bomb containing a glass liner. The reaction mixture was warmed to 135±10° C. and 1300 psi for 14 h with vigorous stirring. The vessel was allowed to cool to 60° C., and the ammonia was released slowly. The remaining traces of ammonia were removed by co-evaporation with THF (2×150 mL) under a stream of argon at 60° C. The intermediate 4-hydroxy-2-naphthylamine (2) was not isolated but was immediately converted to the di-tert-butyloxycarbonyl protected compound 3. A solution of di-tert-butyl dicarbonate (175 g, 0.801 mol) in dry THF (300 mL) and N,N-diisopropylethylamine (140 mL, 0.803 mol) were sequentially added to the bomb. The bomb was re-sealed, and the contents were warmed at 100 ° C. with stirring for 4 h. The bomb was cooled to room temperature, opened, and the residue partitioned between saturated aqueous NaCl (800 mL) and ethyl acetate (500 mL). The aqueous phase was extracted with ethyl acetate (200 mL×2). The combined organic layers were dried (magnesium sulfate), filtered, and concentrated under reduced pressure. Chromatography on silica gel (1:8 to 1:4 ethyl acetate/hexane) and recrystallization with ethyl acetate/ethanol/hexane provided pure 77.41 g (69%) of the title compound (3). 1 H NMR (CDCl 3 , 400 MHz) 8.14 (d, 1H, J=8.1 Hz), 7.66 (d, 1H, J=8.1 Hz), 7.43 (dd, 1H, J=6.8, 8.2 Hz), 7.35 (dd, 1H, J=6.8, 8.2 Hz), 7.22 (d, 1H, J=1.8 Hz), 7.15 (br, 1H, NH), 6.69 (s, 1H), 1.59 (s, 9H), 1.37 (s, 9H); 13 C NMR (CDCl 3 ) 153.71, 152.9, 136.11, 135.20, 128.12, 128.01, 126.81, 126.03, 123.61, 107.94, 102.95, 82.98, 82.10, 28.93, 27.69; MS m/z 382.52 (M+Na) + . Example 2 Preparation of N-(tert-butyloxycarbonyl)-4-O-(tert-butyloxycarbonyl)-1-iodo-2-naphthylamine (4) A solution of compound 3 (24.50 g, 68.24 mmol) and N-iodosuccinimide (NIS), (17.70 g, 74.73 mmol) in 250 mL of THF/methanol (1:1) was stirred at −40° C. under argon in the dark for 5 min. Toluenesulfonic acid (0.86 g, 4.52 mmol) was then added, and the reaction mixture was stirred under argon in the dark at −40° C. for 2 h, and then at room temperature for 2 h. The mixture was diluted with ether (800 mL), washed with saturated aqueous NaHCO 3 and saturated aqueous NaCl, dried over magnesium sulfate, filtered and concentrated in vacuo. Flash chromatography on silica gel (ethyl acetate/hexane 1:10) was followed by the isolation of the desired product. Crystallization from ethanol/ethyl acetate/hexane afforded 28.46 g (86%) of the title compound 4. Rf=0.48 (10% ethyl acetate/hexane). 1 H NMR (CDCl 3 , 400 MHz) 8.27 (d, 1H, J=8.0 Hz), 7.98 (dd, 1H, J=1.5, 8.1 Hz), 7.83 (s, 1H), 7.55 (m, 2H), 7.18 (br, 0.8H, NH), 1.62 (m, 18H); MS m/z 508.36 (M+Na) + . Example 3 Preparation of 2-[N-(tert-butyloxycarbonyl)-N-(3-chloro-2-propen-1-yl)amino]-4-O-(tert-butyloxycarbonyloxy)-1-iodonaphthalene (5) To a solution of compound 4 (940 mg, 1.86 mmol) in 20 mL of dry DMF was added NaH (60% in mineral oil, 150 mg, 3.75 mmol) under an argon atmosphere. After stirring the mixture at 0° C. for 30 min, E, Z-1,3-dichloropropene (1.50 mL, 14.57 mmol) was added. The reaction mixture was stirred at 0° C. under argon for 2 h, then neutralized with 1.0 M NaH 2 PO 4 , and extracted with ethyl acetate. The organic layer was dried over magnesium sulfate, filtered and concentrated in vacuo. Flash chromatography on silica gel (ethyl acetate/hexane 1:9) afforded 1.01 g (93%) of the desired compound 5. R fE =0.37, R fZ =0.32 (1:8 ethyl acetate/hexane). (E:Z vinyl chlorides and di-t-boc rotamers). 1 H NMR (CDCl 3 , 400 MHz) 8.26 (d, 2H, J=7.7 Hz), 7.96 (m, 2H), 7.59 (br, 4H), 7.20 (s, 1H), 7.16 (s, 1H), 6.17-6.07 (m, 4H), 4.64 (dd, 1H, J=6.2, 15.2 Hz), 4.53 (dd, 1H, J=6.2, 14.7 Hz), 4.31 (dd, 1H, J =6.0, 15.0 Hz), 3.84 (dd, 1H, J=7.5, 15.0 Hz), 1.58 (S, 9H); 1.33 (s, 9H); 3 C NMR (CDCl 3 ) 153.78, 151.08, 150.98, 133.31, 133.29, 128.66, 128.61, 127.50, 127.41, 126.41, 121.68, 119.03, 84.22, 84.11, 80.99, 77.20, 28.20, 27.66; MS m/z 582.8 (M+Na) + . Example 4 Preparation of 5-(O-tert-butyloxycarbonyl)oxy-3-[N-(tert-butyloxycarbonyl)amino-1-(chloromethyl)-1,2-dihydro-3H-benz(e)indole (6) To a solution of compound 5 (1.36 g, 2.43 mmol) in dry benzene (100 mL) were added tri-n-butyltin hydride (0.70 mL, 2.52 mmol) and 2,2′-azobis(isobutyronitrile) (AIBN) (30 mg, 0.18 mmol). The mixture was stirred under argon at room temperature for 30 min and then refluxed at 80° C. for 2 h. The reaction mixture was cooled, and the solvent was removed in vacuo. Flash chromatography on silica gel (ethyl acetate/hexane 1:9) afforded 1.01 g (94%) of the desired compound 6. R f =0.34 (1:9 ethyl acetate/hexane); 1 H NMR (CDCl 3 , 400 MHz) 8.12 (br, 1H), 7.91 (d, 1H, J=8.4 Hz), 7.69 (d, 1H, J=8.4 Hz), 7.50 (dt, 1H, J=1.0, 6.9, 7.0 Hz), 7.37 (dt, 1H, J=0.9, 6.9, 6.9 Hz), 4.27 (br, 1H), 4.12 (t, 1H, J=9.0+10.0 Hz), 3.99 (m, 1H), 3.90 (dd, 1H, J=2.4, 11.0 Hz), 3.45 (t, 1H, J=10.8+10.8 Hz), 1.58 (S, 18H); 13 C NMR (CDCl 3 ) 152.27, 151.84, 147.99, 130.17, 127.62, 124.33, 122.46, 122.22, 108.95, 83.78, 52.80, 46.13, 28.36, 27.79; MS m/z 456.9 (M+Na) + . Resolution of (6): The enantiomeric mixture of compound 6 (1.0 g in 20 mL of ethyl acetate) was resolved on an BPLC preparative column (20 mm, 7.5×50 cm, packed with Diacel Chiralcel OD) using 15% isopropanol-hexane eluant (180 mL/min). The two enantiomers eluted with retention times of 18.5 minutes [6a (+) enantiomer] and 35.8 minutes [6b (−) natural (1S) enantiomer]. 6b (−)-(1S): [α] 25 =−49.6° (c=5.25 CHCl 3 ). Example 5 Preparation of 5-hydroxy-3-amino-1-[S]-(chloromethyl)-1,2-dihydro-3H-benz(e)indole (7) To a solution of 6b (100 mg, 0.25 mmol) in 5 mL of ethyl acetate, was added conc. HCl (0.2 mL) and triethylsilane (0.2 mL). After stirring for 3 h under argon, the mixture was diluted with 10 mL of 1:1 dichloromethane/toluene and evaporated to dryness. The dry solid was co-evaporated three times with dichloromethane/toluene and then immediately used for coupling to di-indole compounds without further purification, (˜90% pure), MS m/z 234.78 (M+H) + . Examples 6-15 Exemplary Synthesis of DCl According to the Scheme of Path A (FIG. 2 ) Example 6 Preparation of tert-Butyl-5-nitroindole-2-carboxylate (10) To a stirred solution of ethyl-5-nitroindole-2-carboxylate (8) (25.0 g, 106.8 mmol), in 500 mL of THF-methanol (1:1, v/v) at room temperature, was added a solution of NaOH (40 g, 1.0 mmol) in 300 mL of water. The resulting deep red-brown solution was stirred for 3 h, then quenched by acidification to pH 1 with dilute HCl. The precipitated product was collected by vacuum filtration, and the remaining dissolved product was extracted with T HF/ethyl acetate (1:2, v/v, 2×400 mL). The precipitate was dissolved in THF and this solution was combined with the organic layers from the extractions, supra. Drying over magnesium sulfate, filtration, concentration in vacuo, and crystallization of the residue from THF/ethyl acetate/hexane afforded 21.1 g (96% yield) of 5-nitroindole-2-carboxylic acid (9). 1 H NMR (DMSO), 11.50 (s, 1H), 7.20 (d, 1H, J=8.4 Hz), 6.85 (s, 1H), 6.70 (m, 2H). To a stirred solution of 9 (12.8 g, 61.2 mmol) in dry THF (200 mL) under argon was added oxalyl chloride (12.0 mL, 137.5 mmol) followed by DMF (0.1 mL), which caused a vigorous evolution of gas. After 40 min, the reaction mixture was evaporated to dryness. The resulting solid was re-dissolved in THF (150 mL), cooled to ˜30° C., and stirred under argon. A solution of potassium t-butoxide (1.0 M in THF, 140 mL, 140 mmol) was then added dropwise over 45 min, and stirring was continued for an additional 45 min. The reaction was quenched with 600 mL of water, neutralized with few drops of a 10% aqueous solution of H 3 PO 4 and extracted with ethyl acetate (3×400 mL). The organic extracts were washed with saturated aqueous NaHCO 3 , water, and then dried over magnesium sulfate, filtered, concentrated and crystallized with ethanol/hexane to afford compound 10 (9.62 g, 85% yield). R f =0.35 (1:5 Ethyl acetate/Hexane); 1 H NMR (CDCl 3 ), 11.63 (s, 1H), 8.66 (dd, 1H, J=0.5, 1.3 Hz), 8.20 (dd, 1H, J=0.5, 9.0 Hz), 7.48 (dd, 1H, J=0.5, 9.1 Hz), 7.28 (dd, 1H, J=0.9, 11.1 Hz), 1.63 (s, 9H); 13 C NMR 160.39, 142.12, 138.11, 132.10, 126.78, 120.22, 119.83, 111.98, 109.82, 82.91, 28.26; MS m/z 285.43 (M+Na) +. Example 7 Preparation of tert-butyl 5-aminoindole-2-carboxylate (11) A 500 mL Par hydrogenation bottle was charged with compound 10 (5.80 g, 22,14 mmol), 10% Pd/C (0.6 g) and methanol/THF (150 mL, 1:4 v/v), and purged with hydrogen. The reaction mixture was shaken with 50 psi H 2 over night. The catalyst was removed by filtration and the solvent was evaporated to give 4.95 g (97% yield) of the title compound 11 as brown solid 1 H NMR (DMSO), 11.42 (s, 1H), 7.18 (d, 1H, J=8.3 Hz), 6.83 (s, 1H), 6.71 (s, 1H), 6.67 (d, 1H, J=8.4 Hz), 1.62 (s, 9H). This product is unstable and therefore it was immediately used in the following step. Example 8 Preparation of tert-butyl 5-(5′-nitroindole-2′-yl-carbonyl amino)indole-2-carboxylate (12) To a mixture of compounds 9 (4.70 g, 22.81 mmol) and 11 (5.20 g, 22.41 mmol) in DMF (200 mL) were added under argon O-(benzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium tetraflouroborate (TBTU, 10.5 g, 32.70 mmol) and diisopropylethylamine (DIPEA, 8.0 mL, 45.83 mmol). The reaction mixture was stirred overnight. The mixture was concentrated and then suspended in ethyl acetate and aqueous NaHCO 3 (satd.). The solid compound was filtered, washed with water, and then re-suspended with aqueous 1 M NaH 2 PO 4 , pH 3.0, filtered, and washed again with water. The solid was then dried under vacuum to yield 12 (8.40 g, 89% yield). R f =0.31 (1:2 THF/hexane); 1 H NMR(DMSO), 12.43 (s, 1H), 11.69 (s, 1H), 10.41 (s, 1H), 8.77 (d, 1H, J=2.2 Hz), 8.13 (dd, 2H, J=2.3, 9.0 Hz), 7.64 (t, 2H, J=9.2 Hz), 7.47 d, 1H, J=8.9 Hz), 7.08 (s, 1H), 1.59 (s, 9H); 13 C NMR (DMSO), 161.48, 159.53, 142.19, 140.38, 136.30, 135.27, 132.28, 130.30, 127.43, 127.25, 120.57, 120.12, 114.08, 113.74, 108.22, 106.64, 81.74, 28.84; MS m/z 443.85 (M+Na) + . Example 9 Preparation of tert-butyl 5-(5′-aminoindol-2′-yl-carbonyl amino)indole-2-carboxylate (13) A 250 mL Parr hydrogenation bottle was charged with compound 12 (2.40 g, 5.71 mmol), 10% Pd/C (0.3 g), and DMA (50 mL), and purged with hydrogen. The reaction mixture was shaken with 40 psi H 2 over night. The catalyst was removed by filtration and the solvent was evaporated to give 2.05 g (92% yield) of the title compound 13 as a brown solid. 1 H NMR (DMSO), 11.75, (s, 1H), 11.67 (s, 1H), 10.17 (s, 1H), 8.10 (d, 1H, J=1.2 Hz), 7.59 (t, 2H, J=8.8 Hz), 7.45 (m, 1H), 7.35 (m, 1H), 7.17 (dd, 1H, J=0.8, 8.0 Hz), 7.06 (d, 1H, J=2.0 Hz), 1.57 (s, 9H); MS m/z 390.72 (M+Na) + . This product is unstable and therefore it was used immediately in the following step. Example 10 Preparation of tert-butyl 5-[5′-(3″-methyldithiopropionyl)indol-2′-yl-carbonyl amino]indole-2-carboxylate (14a) To a solution of 13 (2.0 g, 5.12 mmol)) in DMA (30 mL) was added of 3-(methyldithio)propionic acid (0.90 g, 5.92 mmol), EDC (3.0 g, 15.33 mmol) and DIPEA (0.90 mL, 5.12 mmol). The reaction mixture was stirred over night under argon, and then diluted with 70 mL of 1.0 M NaH 2 PO 4 , pH 6.0 and extracted with THF/ethyl acetate (1:1, 4×70 mL). The organic layers were combined, dried over magnesium sulfate, filtered and evaporated. The residue was purified by silica gel chromatography (1:3 acetone/toluene) and crystallized from TBF/hexane to yield compound 14a (2.30 g, 86% yield). Mp=279-283° C. (dec),R f =0.31 (1:3 THF/toluene); 1 H NMR (CD 3 COCD 3 ), 10.75 (d, 1H, J=3.07 Hz), 9.50 (s, 1H), 9.14 (s, 1H), 8.20 (d, 1H, J=2.0 Hz), 8.14 (d, 1H, J=1.8 Hz), 7.62 (dd, 1H, J2.0, 8.9 Hz), 7.46 (dd, 2H, J=0.7, 8.1 Hz), 7.34 (dd, 1H, J=2.0, 10.8 Hz), 7.26 (d, 1H, J=1.5 Hz), 7.07 (dd, 1H, J=0.9, 2.1 Hz), 3.05 (t 2H, J=7.1 Hz), 2.76 (t 21, J=7.0 Hz), 2.42 (s, 3H), 1.57 (s, 9H); 13 C NMR 169.42, 161.58, 160.32, 135.31, 134.76, 133.56, 133.40, 133.12, 130.86, 128.72, 128.27, 120.27, 118.75, 113.69, 113.09, 113.02, 112.69, 108.27, 103.58, 81.66, 37 28, 34.00, 28.41; MS m/z 547.88 (M+Na) + . Example 11 Preparation of 5-[5′-(3″-methyldithiopropionyl)indol-2′-yl-carbonyl amino]indole-2-carboxylic acid (15a) A mixture of compound 14a (300 mg, 0.57 mol) and Et 3 SiH (1.5 mL) in dichloromethane (30 mL) was stirred under argon. Trifluoroacetic acid (7.0 mL) was added and the mixture was stirred for 3 h, and then diluted with toluene (25 mL). The mixture was evaporated to dryness and crystallized with THF/toluene/hexane to yield compound 15a (245 mg, 92% yield). 1 H NMR (DMSO), 11.71 (s, 1H), 11.61 (s, 1H), 10.10 (s, 1H), 9.92 (s, 1H), 8.11 (d, 1H, J=1.9 Hz), 8.02 (d, J=1.7 Hz), 7.55 (dd, 1H, 2.0, 11.0 Hz), 7.42 (d, 1H, J=8.8 Hz), 7.39 (d, 1H, J=8.8 Hz), 7.34 (d, 1H, J=2.0 Hz), 7.31 (dd, 1H, J=2.0, 8.8 Hz), 7.08 (d, 1H, J=1.3 Hz), 3.06 (t, 2H, J=7.0 Hz), 2.75 (t, 2H, J=7.0 Hz), 2.45 (s, 3H); 13 C NMR DMSO), 168.70, 162.79, 159.47, 134.37, 133.56, 132.44, 131.98, 131.64, 126.96, 126.75, 119.62, 117.74, 113.04, 112.46, 112.35, 111.44, 107.36, 103.37, 36.03, 33.01; MS 490.81 (M+Na) + . Example 12 Preparation of (S)-N-[2-{(1-chloromethyl)-1,2-dihydro-5-hydroxy-3H-benz(e)indol-3-yl}carbonyl]-1H-indol-5-yl]-5-[(3-methyldithio-1-oxopropyl)-amino]-1H-indole-2-carboxamide (16a) (DC1SMe) To a solution of compounds 7 (55 mg, 0.20 mmol) and 15a (100 mg, 0.21 mmol) in DMA (7.0 mL) was added EDC (120 mg, 0.62 mmol) under argon. The reaction mixture was stirred overnight, then a few drops of 50% acetic acid were added, and the mixture was evaporated to dryness. The residue was purified by column chromatography over silica gel (20% to 30% acetone in toluene) and crystallized with THF/toluene/hexane to afford DClSMe (16a) (108 mg, 79% yield).Rf=0.40 (3:7 acetone/toluene); 1 H NMR (CD 3 COCD 3 ) 10.91 (s, 1H), 10.88 (s, 1H), 9.64 (s, 1H), 9.56 (s, 1H), 9.27 (s, 1H), 8.35 (d, 1H, J=1.9 Hz), 8.25 (d, 1H, J==8.0 Hz), 8.17 (d, 1H, J=1.9 Hz), 8.07 (s, 1H), 7.88 (d, 1H, J=8.3 Hz), 7.64 (dd, 1H, J=2.0, 8.1 Hz), 7.58-7.50 (m, 3H), 7.38-7.35 (m, 2H), 7.31 (d, 1H, J=1.7 Hz), 7.26 (d, 1H, J=1.7 Hz), 4.86 (dd, 1H, J=8.7, 11.0 Hz), 4.80 (dd, 1H, J=2.3, 10.9 Hz), 4.30 (m, 1H), 4.07 (dd, 1H, J=3.1, 11.0 Hz), 3.83 (dd, 1H, J=8.4, 11.2 Hz), 3.09 (t, 2H, J=7.1 Hz), 2.83 (t, 2H, J=7.1 Hz), 2.45 (s, 3H); 13 C NMR 169.56, 161.10, 160.43, 155.13, 143.50, 134.78, 134.46, 133.55, 133.34, 133.03, 132.57, 131.21, 128.80, 128.69, 128.21, 124.22, 124.02, 123.53, 123.44, 120.16, 118.79, 116.45, 113.91113.02, 112.95, 112.73, 106.78, 103.72, 101.63, 56.01, 47.73, 43.10, 37.25, 34.01, 23.00; MS m/z 706.71 (M+Na) + , 708.58, 707.71, 722.34 (M+K) + , 724.42. Example 13 Preparation of tert-butyl5-[5′-(3″-(2-pyridyldithio)propionyl)indol-2′-yl-carbonyl amino]indole-2-carboxylate (14b) To a solution of compound 13 (1.00 g, 2.56 mmol) in DMA (15 mL) was added of 3-(2-pyridyldithio)propionic acid (0.475 g, 2.21 mmol), EDOC (1.26 g, 6.56 mmol), and DIPEA (0.20 mL). After stirring under argon overnight, the mixture was diluted with 70 mL of 1.0 M NaH 2 PO 4 , pH 3.0 and extracted with THF/ethyl acetate (1:1, 4×60 mL). The organic layers were combined, dried over magnesium sulfate, filtered, evaporated, and purified by silica gel chromatography (1:5 THF/dichloromethane). The product was isolated and recrystallized with THF/ethyl acetathexane to yield 1.13 g (87% yield) of the title compound 14b. Mp=285-290 (dec), R f =0.31 (1:5 THF/toluene); 1 H NMR (CD 3 COCD 3 ), 10.78 (d, 2H, J=14.3 Hz), 9.52 (s, 1H), 9.23 (s, 1H), 8.45 (dd, 1H, J=0.9, 4.8 Hz), 3.23 (d, 1H, J=1.9 Hz), 8.17 (d, 1H, J=1.8 Hz), 7.84 (dd, 1H, J=1.0, 8.1 Hz), 7.78 (m, 1H), 7.64 (dd, 1H, J=2.1, 8.9 Hz), 7.49 (t 2H, J=88 Hz), 7.35 (dd, 1H, J=2.0, 8.9 Hz), 7.29 (d, 1H, J=1.5 Hz), 7.25 (m, 1H), 7.10 (dd, 1H, J=0.8, 2.1 Hz), 3.21 (t 2H, J=7.0 Hz), 2.85 (t 2H, J=7.0 Hz), 1.60 (s, 9H); 13 C NMR 1.69,15, 161.57, 160.86, 150.44, 138.22, 135.30, 134.78, 133.58, 133.13, 130.86, 128.27, 125.75, 121.73, 120.26, 120.05, 118.75, 113.68, 113.09, 113.03, 112.70, 108.26, 103.56, 81.64, 36.74, 35.25, 28.41; MS m/z 610.48 (M+Na) + , 626.56 (M+K) + . Example 14 Preparation of 5-[5′-(3″-(2-pyridyldithio)propionyl)indol-2′-yl-carbonyl amino]indole-2-carboxylic acid (15b) A mixture of compound 14b (115 mg, 0.195 mol) and Et 3 SiH (0.30 mL) in dichloromethane (4.0 mL) was stirred to under argon. To the milky mixture was added trifluoroacetic acid (1.0 mL), and the mixture became clear. After stirring for 2 hrs, the reaction mixture was diluted with 5 mL of toluene. The mixture was evaporated to dryness and crystallized with THF/toluene/hexane to yield of 93 mg (90% yield) of compound 15b. 1 H NMR (DMSO), 12.92 (br, 0.7H), 11.74 (s, 1H), 11.63 (s, 1H), 10.11 (s, 1H), 9.92 (s, 1H), 8.47 (dd, 1H, J=0.9, 4.6 Hz), 8.13 (s, 1H), 8.02 (s, 1H), 7.81 (m, 2H), 7.56 (d, 1H, J=9.0 Hz), 7.41 (m, 1H), 7.34 (s, 1H), 7.28-7.21 (m, 2H), 7.10 (s, 1H), 3.15 (t, 2H, J=7.0 Hz), 2.77 (t, 2H, J=6.9 Hz); 13 C NMR 168.34, 162.70, 159.42, 159.16, 149.61, 137.80, 134.34, 133.53, 132.41, 131.88, 131.63, 128.96, 126.90, 126.69, 121.18, 119.60, 119.19, 112.98, 112.42, 112.31, 111.42, 107.47, 35.53, 33.97; MS m/z 532.31, (M+H) + , 553.41, 554.52 (M+Na) + . Example 15 Preparation of (S)-N-[2-{(1-chloromethyl)-1,2-dihydro-5-hydroxy-3H-benz(e)indol-3-yl}carbonyl]-1H-indol-5-yl]-5-[(3-pyridyldithio-1-oxopropyl)-amino]-1H-indole-2-carboxamide, DC1SPy (16b) To a solution of compounds 7 (25 mg, 0.094 mmol) and 15b (50 mg, 0.094 mmol) in 10 mL of DMA was added EDC (120 mg, 0.62 mmol) under argon. After stirring overnight, a few drops of 50% acetic acid and toluene (5 mL) were added, the mixture was evaporated to dryness, and the residue was purified by silica gel chromatography (30% acetone in toluene). The product was isolated and recrystallized from THF/toluene/hexane to afford 48 mg (68% yield) of the title compound 16b. MS m/z 769.43 (M+Na) + , 771.51, 785.62 (M+K) + . Examples 16-20 Exemplary synthesis of DC1 according to the scheme of Path B (FIG. 3 ) Example 16 Preparation of ethyl 5-aminoindole-2-carboxylate (18) A 500 mL Par hydrogenation bottle was charged with ethyl 5-nitroindole-2-carboxylate (8) (5.0 g, 21.36 mmol), 10% Pd/C (0.3 g), methanol/THF (150 mL, 1:4 v/v), and was purged with hydrogen. The reaction mixture was shaken with 40 psi H 2 overnight. The catalyst was removed by filtration and the solvent was evaporated to give 4.10 g (94% yield) of the title compound 18 as a brown solid. 1 H NMR (CDCl 3 ), 8.77 (s, 1H), 7.26 (s, 1H), 7.23 (t 1H, J=0.8 Hz), 7.21 (d, 1H, J=0.7 Hz), 7.03 (dd, 1H, J=0.7, 1.5 Hz), 6.93 (dd, 1H, J=0.7, 1.6 Hz), 6.80 (dd, 1H, J=2.2, 8.6 Hz), 4.38 (dd, 2H, J=7.2, 14.3 Hz), 1.40 (t, 3H, J=7.2 Hz); 13 C NMR (CDCl 3 ) 162.02, 140.30, 138.14, 131.87, 128.45, 127.77, 117.12, 112.50, 107.36, 105.86, 60.87, 14.41. This product is unstable and therefor it was used immediately in next step. Example 17 Preparation of ethyl 5-(5′-nitroindol-2′-yl-carbonyl amino)indole-2-carboxylate (19) To a mixture of compounds 9 (1.020 g, 5.00 mmol) and 18 (1.02 g, 4.95 mmol) in DMF (30 mL) was added TBTU (4.0 g, 12.40 mmol) and DIPEA (1.8 mL) under argon. The reaction mixture was stirred overnight. After concentration, the mixture was diluted with ethyl acetate (30 mL) and saturated NaHCO 3 (150 mL), and the solid was suspended between the two layers. The solid compound was filtered, washed with water and then re-suspended with 1 M NaH 2 PO 4 , pH 3.0, filtered, and washed with water again. The product was dried under vacuum to provide compound 19 (1.543 g, 79% yield). R f =0.31 (1:2 THF/hexane); 1 H NMR (DMSO), 12.45 (s, 1H), 11.90 (s, 1H), 10.43 (s, 1H), 8.77 (d, 1H, J=1.9 Hz), 8.15 (s, 1H), 8.13 (dd, 1H, J=2.2, 9.1 Hz), 7.70 (s, 1H), 7.61 (m, 2H), 7.46 (d, 1H, J=8.9 Hz), 7.18 (s, 1H), 4.35 (dd, 2H, J=7.1, 14.1 Hz), 1.35 (t, 3H, J=7.1 Hz); 13 C NMR (DMSO), 161.22, 158.68, 141.32, 139.50, 135.37, 134.60, 131.47, 128.01, 126.56, 126.38, 119.92, 119.27, 118.59, 113.27, 112.87, 112.60, 107.77, 105.69, 60.43, 14.31; MS m/z 443.85 (M+Na) +. Example 18 Preparation of 5-(5′-nitroindol-2′-yl-carbonyl amino)indole-2-carboxylic acid (20) To a solution of compound 19 (630 mg, 1.60 mmol) in DMSO (15 mL) was added NaOH (1.0 g) in 5.0 mL of H 2 O. After stirring for 1 h, the mixture was concentrated and co-evaporated three time with 10 mL of H 2 O at 60° C. under reduced pressure. The residual solution was diluted with cold methanol and H 2 O, yielding a solid. The solid compound was filtered and dried under vacuum to give compound 20 (530 mg, 90% yield). 1 H NMR (DMSO), 12.48 (s, 1H), 11.75 (s, 1H), 10.44 (s, 1H), 8.77 (s, 1H), 8.15 (s, 1H), 8.10 (d, 1H, J=9.3 Hz), 7.69 (s, 1H), 7.60 (m, 2H), 7.44 (d, 1H, J=8.9 Hz), 7.10 (s, 1H); 13 C NMR (DMSO), 161.91, 158.66, 141.32, 139.52, 135.45, 134.44, 131.26, 128.01, 126.72, 126.39, 119.47, 119.25, 118.02, 113.24, 112.88, 112.48, 107.23, 105.71; MS m/z 386.66 387.85 (M+Na) +. Example 19 Preparation of 1-[S]-(chloromethyl)-5-hydroxy-3-{{5-[5′-nitroindol-2′-yl-carbonyl amino]indole-2-yl}carbonyl}-1,2-dihydro-3H-benz[e]indole (21) To a solution of compounds 7 (20 mg, 0.072 mmol) and 20 (25 mg, 0.068 mmol) in DMA (3.0 mL) was added EDC (40 mg, 0.20 mmol) under argon. The reaction mixture was stirred overnight, a few drops of 50% acetic acid was added, and the mixture was evaporated to dryness. The residue was purified by preparative TLC on silica (40% acetone in toluene) to afford 25 mg of compound 21. 1 H NMR (DMF-d 7 ) 12.54 (s, 1H), 11.73 (s, 1H), 10.60 (s, 1H), 10.58 (s, 1H), 8.80 (d, 1H, J=2.3 Hz), 8.42 (d, 1H, J=1.9 Hz), 8.25 (d, 1H, J=8.5 Hz), 8.19 (dd, 1H, J=2.1, 9.1 Hz), 8.09 (br, 1H), 7.95 (d, 1H, J=8.3 Hz), 7.82 (d, 1H, J=1.5 Hz), 7.79 (d, 1H, J=9.1 Hz), 7.74 (dd, 1H, J=2.0, 8.9 Hz), 7.62 (d, 1H, J=8.8 Hz), 7.58 (dt, 1H, J=1.7, 7.0+7.0 Hz), 7.42 (dt, 1H, J=1.2, 7.0+7.0 Hz), 7.33 (d, 1H, J=1.7 Hz), 4.91 (t, 1H, J=11.0 Hz), 4.77 (dd, 1H, J=2.1, 11.1 Hz), 4.33 (m, 1H), 4.13 (dd, 1H, J=3.1, 11.1 Hz), 3.97 (dd, 1H, J=7.9, 11.1 Hz); 13 C NMR 163.35, 161.48, 160.05, 155.79, 142.98, 137.18, 135.03, 133.22, 133.16, 131.50, 128.85, 128.45, 128.11, 124.62, 124.02, 123.76, 120.33, 119.36, 118.70, 116.45, 114.00, 113.08, 106.97, 105.02, 101.53; MS m/z 602.96 (M+Na) + , 604.78, 603.81, 618.64 (M+K) + , 620.48. Example 20 Preparation of (S)-N-[2-{(1-chloromethyl)-1,2-dihydro-5-hydroxy-3H-benz(e)indol-3-yl}carbonyl]-1H-indol-5-yl]-5-[(3-methyldithio-1-oxopropyl)-amino]-1H-indole-2-carboxamide (16a) (DC1-SMe) A solution of compound 21 (10 mg, 0.017 mmol) in DMA (2.5 mL) was treated with Pd/C (10 mg), 5 μl of HCl (conc.) and DMA (2.5 mL). After the air was removed evacuated, hydrogen was introduced via a hydrogen balloon overnight. The catalyst was removed by filtration and the solvent was evaporated to give compound 22 as a brown solid. The solid compound was used directly without further purification. To a solution of compound 22 in DMA (2 mL) under argon was added 3-(methyldithio)propionic acid (5 mg, 0.032 mmol) and of EDC (15 mg, 0.078 mmol). After stirring overnight, two drops of 50% acetic acid were added to the mixture and the mixture was evaporated to dryness. The residue was purified by preparative silica gel chromatography (40% acetone in toluene) to afford 6 mg of DC1-SMe (16b). MS m/z 706.66 (M+Na) + , 708.79, 707.86; 1 H NMR data is the same as above DC1. Certain patents and printed publications have been referred to in the present disclosure, the teachings of which are hereby each incorporated in their respective entireties by reference. While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one of skill in the art that various changes and modifications can be made thereto without departing from the spirit and scope thereof.
Improved synthesis of seco(−)CBI (5-hydroxy-3-amino-1-[S]-(chloromethyl)-1,2 -dihydro-3H-benz(e)indole): and improved syntheses therefrom of a wide variety of CC-1065 analogs that comprise a cyclopropabenzidole (CBI) alkylating moiety, and which are collectively DC 1 and its derivatives, for the synthesis of cell-targeted therapeutic agents.
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CLAIM OF PRIORITY [0001] This application is a national phase filing under 35 USC §371 of PCT Application serial number PCT/DE2015/000378 filed on Jul. 30, 2015, and claims priority therefrom. This application further claims priority to German Patent Application Number DE 10 2014 001 236.5 filed on Aug. 2, 2014. PCT Application Number PCT/DE2015/000378 and German Patent Application Number DE 10 2014 001 236.5 are each incorporated herein by reference in its entirety. FIELD [0002] The present invention relates to a casting mold that is produced with the aid of a powder-based layering method, a use of the casting mold and a method for the production thereof. BACKGROUND [0003] A method for producing three-dimensional objects from computer data is described in the European patent specification EP 0 431 924 B1. In this method, a particulate material is applied in a thin layer to a platform, and a fluid is selectively printed on the particulate material with the aid of a print head. In the area onto which the fluid is printed, the particles bind to each other, and the area solidifies under the influence of the fluid and, if necessary, an additional hardener. The platform is then lowered by a distance of one layer thickness into a build cylinder and provided with a new layer of particulate material, which is also printed as described above. These steps are repeated until a certain, desired height of the object is reached. A three-dimensional object is thereby produced from the printed and solidified areas. [0004] After it is completed, this object produced from solidified particulate material is embedded in loose particulate material and is subsequently removed therefrom. This is done, for example, using an extractor. This leaves the desired objects, from which powder deposits are removed, for example by manual brushing. [0005] Of the layering techniques, 3D printing based on powdered materials and the supply of fluids with the aid of a print head is the fastest method. [0006] This method may be used to process different particulate materials, including natural biological raw materials, polymers, metals, ceramics and sands (not an exhaustive list). [0007] The strengths of the submitted method lie in the high volume capacity and the cost-effective production. However, the material properties often lag behind those known from conventional production. [0008] For example, a material may be produced which uses sand particles as the base material and is bound by cement. This material is a type of concrete. The strength of a material of this type is, however, much lower than that of conventionally produced concrete, due to its porosity. [0009] Sand particles having other binding systems may also be processed by the powder-based 3D printing process. This includes, among other things, cold resin binding, which is used in foundry practice as well as in 3D printing. [0010] Inorganic binders are also state of the art in this area. These are the most environmentally friendly alternative to cold resin binders in foundry practice. [0011] These materials also do not directly achieve strengths that are relevant, e.g., for construction. In principle, only a few materials may be processed into dense and high-strength materials with the aid of the powder-based 3D printing method. These materials are essentially polymers. [0012] The use of two-stage methods is one way around this limitation in 3D printing. In this case, casting in 3D-printed molds is one option. This method is state of the art in the area of metal casting. [0013] In the area of concrete materials or cold-castable polymers, processing with the use of 3D-printed molds is not common practice for casting methods. On the one hand, this is due to the lack of the breakout and core removal capability, which is due to the absence of the solidity-reducing effect of heat in the cold casting process. On the other hand, an undesirable bonding of the casting material to the mold may build up during cold casting, since a 3D-printed casting mold has a relatively high porosity for cold casting methods, into which the casting material may penetrate. [0014] It is known from the prior art that reusable molds may generally be used for casting concrete parts. [0015] For example, coated wooden boards are used as formwork when casting straight walls. These boards are additionally pretreated with a formwork oil, thereby preventing the concrete from sticking to the multiple-use boards. [0016] To remove the formwork, these boards are usually peeled away from the concrete part by pounding them with a hammer after casting. [0017] More complex shapes made of concrete are often produced with the aid of silicone molds. In this case, the silicone mold is in the form of a negative model. The mold must then be laboriously produced using a model, which acts as a positive mold for the silicone casting. A model of this type may be produced, for example, using conventional techniques, such as milling in wood or plastic or using additive methods. To lend the silicone casting mold the necessary strength, an additional substructure is necessary, which makes the method even more complex. Like with the formwork boards, a mold release agent must frequently be applied to the silicone casting mold prior to casting. [0018] The silicone mold may then be removed after the casting material solidifies by simply pulling the part away from the mold. However, the substructure must first be removed for this purpose. [0019] These two methods cannot be used for molds which have been produced by powder-based 3D printing with the aid of cold resin binder. [0020] Due to the porosity of the molds, conventional mold release agents are unable to prevent the casting material from penetrating the mold. Instead, the mold release agents infiltrate the molded part and enter the interior without having any effect on the surface. SUMMARY [0021] A number of terms in the invention are explained in greater detail below. [0022] Within the meaning of the invention, “3D printing method” relates to all methods known from the prior art which facilitate the construction of components as three-dimensional molds and are compatible with the method components and devices described. [0023] Within the meaning of the invention, “selective binder application” or “selective binder system application” may take place after each particulate material application or irregularly, depending on the requirements of the molded body and for the purpose of optimizing the production of the molded body, i.e., non-linearly and not in parallel after each particulate material application. “Selective binder application” or “selective binder system application” may thus be set individually and during the course of producing the molded body. [0024] “Molded body” or “component” within the meaning of the invention are all three-dimensional objects that are produced with the aid of the method according to the invention and/or the device according to the invention and which have a nondeformability. [0025] All materials known for powder-based 3D printing, in particular sands, ceramic powders, metal powders, plastics, wood particles, fibrous materials, celluloses and/or lactose powders, may be used as “particulate materials.” The particulate material is preferably a dry, free-flowing powder. However, a cohesive, firm powder may also be used. [0026] “Build space” is the geometric place in which the particulate material feedstock grows during the build process by repeated coating with particulate material. The build space is generally delimited by a base, the building platform, by walls and an open cover surface, the build plane. [0027] “Casting material” within the meaning of this invention is any castable material, in particular materials in which no temperatures arise during processing which could weaken a cold resin binding and which thus promote breakout from the mold. [0028] A “concrete material” within the meaning of this invention is a mixture of an additive (e.g., sand and/or gravel or the like) and a hydraulic binder, the mixing water being used up by the solidification reaction. A concrete material is also a possible casting material. [0029] “Porosity” within the meaning of the invention is a labyrinthine structure of cavities which occur between the particles bound in the 3D printing process. [0030] The “seal” acts at the geometric boundary between the printed mold and the cavity to be filled. It superficially closes the pores of the porous molded body. [0031] “Black wash” designates a fluid which contains particles and does not seal the porosity but only reduces the pore diameter on the surface of the mold. [0032] “Hydrostatic pressure” is used as a general term for all pressures which arise by the action of the fluid column of the casting material. [0033] “Low strength” in terms of sealing means that the seal does not resist any strong forces during breakout from the mold. [0034] “Cold casting methods” are understood to be, in particular, casting methods in which the temperature of the casting mold and the core do not reach the decomposition or softening temperature of the molding material before, during and after the casting process. The solidity of the mold is not influenced by the casting process. The opposite thereof would be metal casting methods, in which the mold is, in general, slowly destroyed by the hot casting compound. [0035] The term “treated surface” designates a surface of the casting mold, which is treated in a preferably separate step after the mold is printed and cleaned. This treatment is frequently an application of a substance to the surface and thus also in the areas of the mold or core near the surface. All conceivable methods may be considered for application. [0036] It is desirable from an economical point of view to implement casting molds for cold casting by means of 3D-printed molds, in particular for more complex molds. [0037] The object of the present invention is to provide a casting mold, in particular for use in cold-casting methods, which is produced with the aid of a powder-based layering method, the final casting mold having a treated surface. [0038] The treated surface may, for example, prevent the casting material from penetrating the molded body, due to the hydrostatic pressure or capillary effects. [0039] Moreover, it could also be that the forces are low during the breakout of porous bodies from the mold due to the surface treatment, since the seal may be drawn out of the pores of the porous molded material by the mold breakout process, and air may then subsequently flow through the porous mold. [0040] Preferred specific embodiments are illustrated below. [0041] According to one preferred specific embodiment of the invention, the treated surface (or the surface treatment) comprises a sealing, a coating, a processing and/or another treatment. [0042] The treated surface should preferably have a lower porosity than the casting mold after it is produced. [0043] In another aspect, the invention relates to a use of the casting mold according to the invention to produce cold-cast parts as a lost-wax casting mold and/or as a continuous casting mold. [0044] In particular, the casting molds according to the invention may be used to produce concrete cast parts and/or cold-cast polymer components. [0045] In yet another aspect, the present invention relates to a method for producing casting molds, in particular for use in cold-casting methods, the casting mold being built with the aid of a powder-based layering method, and the surface of the casting mold being treated. [0046] A powder bed-based 3D printing method is preferably used for the layering method, and a cold resin binding system is even more preferably used. [0047] If the surface is additionally sealed with a hydrophobic material, as needed, the penetration of the casting material into the pores of the casting mold may be effectively limited. [0048] Another possibility is to modify the porosity of the surface of the casting mold with the aid of an infiltrate. [0049] This may be done, for example, with the aid of an epoxy resin, a polyurethane, an unsaturated polyester, a phenol/resol resin, an acrylate and/or a polystyrene. [0050] It is furthermore possible to modify the porosity of the surface with the aid of a black wash and/or dispersion, in particular a zirconium oxide-, aluminum oxide-, calcium oxide-, titanium oxide-, chalk- or silicic acid-based black wash and/or a plastic-, cellulose-, sugar-, flour- and/or salt-based solution. [0051] The porosity of the surface may furthermore be modified or sealed with the aid of a grease, oil, wax and/or hot water-soluble substances. BRIEF DESCRIPTION OF THE DRAWINGS [0052] Brief description of the figures, which represent preferred specific embodiments: [0053] FIG. 1 : shows a schematic representation of the components of a powder-based 3D printer in a sectional isometric view; [0054] FIG. 2 : shows a representation of a simple cast part without undercuts; [0055] FIG. 3 : shows a representation of a complex cast part, including undercuts; [0056] FIG. 4 : shows a representation of a set of multiple-use molds for producing the simple cast part; [0057] FIG. 5 : shows a sectional representation of ejectors and assembly aids for a multiple-use casting mold; [0058] FIG. 6 : shows a representation of a set of single-use molds for producing the complex cast part; [0059] FIG. 7 : shows a sectional view of a component treated according to the invention; [0060] FIG. 8 : shows an illustration of the mold breakout process with a treatment according to the invention. DETAILED DESCRIPTION [0061] One example of a device for producing a molded part according to the present invention includes a powder coater ( 101 ). Particulate material is applied thereby to a building platform ( 102 ) and smoothed ( FIG. 1 ). The applied particulate material may be made from a wide range of materials; according to the invention, however, sand is preferred for reasons of its low cost. This sand is precoated, for example, with an activator component. The height of powder layers ( 107 ) is determined by the building platform ( 102 ). It is lowered after one layer has been applied. During the next coating operation, the resulting volume is filled and the excess smoothed. The result is a nearly perfectly parallel and smooth layer of a defined height. [0062] After a coating process, a fluid is printed onto the layer with the aid of an ink-jet print head ( 100 ). The print image corresponds to the section of the component in the present build height of the device. The fluid strikes and slowly diffuses into the particulate material. [0063] The fluid reacts with the activator in the particulate material to form a polymer. The latter binds the particles to each other. [0064] In the next step, the building platform ( 102 ) is lowered by the distance of one layer thickness. The steps of layer construction, printing and lowering are now repeated until the desired component ( 103 ) is completely produced. [0065] The component ( 103 ) is now complete, and it is located in the powder cake ( 114 ). In the final step, the component is freed of the loose particulate material and cleaned with compressed air. [0066] A component produced in this manner forms the basis for the present invention. The use of these molds may be divided into two areas: single-use molds and multiple-use molds. According to the present invention, they may be used in cold-casting methods. [0067] FIG. 2 shows a simple cast part ( 200 ). It is economical to achieve multiple castings with the aid of one mold. A larger and more complex component is represented, for example, by a sink ( 300 ) in FIG. 3 . The sink has a bowl-shaped formation ( 301 ) in its middle. An opening ( 303 ) for the later drain is situated in its center. Another opening ( 302 ) for the faucet is situated in the rectangular part of the basin. [0068] As a single-use mold ( 600 ), breakout is achieved by destroying the mold. The mold is expediently produced as a thin bowl. The structure is additionally reinforced by means of ribbing to withstand the hydrostatic pressures. FIG. 6 shows a mold of this type. The mold is designed in two parts ( 600 , 601 ). [0069] FIG. 4 shows a multiple-use mold. It comprises two halves ( 400 , 401 ), each of which has a thick-walled design, and into which the cavity ( 402 ) for the casting material is introduced. A sprue ( 403 ) is also provided. [0070] The mold ( 400 , 401 ; 600 , 601 ) may be produced, for example, from a sand having an average grain size of 140 μm, which was premixed with a hardener for a so-called cold resin in the amount of 0.3 wt %. The binding process preferably takes place with a concentration of cold resin in the range of 1.0 to 2.5 wt %. [0071] After the printing process, the mold may be removed from the loose sand and cleaned. [0072] Different methods may be used to modify the pore size. For example, an infiltration with a two-component polymer is possible. However, the material must be used in such a way that, according to the invention, pores which facilitate easy mold breakout remain on the surface after treatment. For this purpose, the mold is treated, for example, with an adapted seal, which is processed at room temperature and does not develop high strengths. [0073] It is likewise possible to additionally use a black wash from the metal casting field. Smaller particles are applied to the surface in this case. The effective pore cross section is modified thereby. As a result, it is possible to prevent, for example, the mechanically weak seal according to the invention from being pressed into the mold due to high hydrostatic pressures. [0074] Grease may be used as a simple seal according to the invention. The grease may be applied to the mold by spreading or spraying it on. The grease muse be suitably selected for the task. Too heavy a grease may be difficult to process. Too thin a grease or oil infiltrates the mold and thus no longer provides a sealing function. [0075] After spreading or brushing, the grease may be additionally smoothed. A superficial application of heat is suitable for this purpose. This may be done, for example, with a hot air gun or a blowtorch. Thoroughly heating the mold is not desirable, since this may lead to the possibility of leaks in the seal. [0076] The use of wax is also possible according to the invention. The wax is expediently liquefied by heating for processing. The low viscosity must be increased by means of a thickener; for example, polystyrene microgranulates may be used for this purpose. It is also possible to use hydrophobic solvents, such as the alkanes or benzine, to create a wax solution whose viscosity may be effectively adjusted. [0077] A seal made from hot water-soluble polyvinyl alcohol may also be created. This material is dissolved in hot water and applied to the preheated mold. The mixing water of a concrete is unable to attack the seal. [0078] FIG. 7 shows the process on the microscopic level. The molded body is constructed with the aid of particles ( 700 ), which are bonded to each other. Fine particles ( 702 ) collect on the geometric component boundary ( 701 ) in the event of a black-washed component. The seal ( 703 ) seals the surface water-tight. [0079] The molds prepared in this manner are subsequently equipped with additional function components. [0080] For example, ejectors ( 500 , 501 ) may be inserted into multiple-use molds for easier breakout from the mold. Depending on the expected breakout forces, the seat of the ejectors in the printed mold was reinforced in advance, e.g., using an epoxy resin infiltration. The ejectors may be designed as bolts ( 501 ), which engage with a nut ( 500 ), which may be countersunk into the printed part. A force is then generated between the mold and the cast part by applying a torque to the bolt. [0081] The mold may also be provided with centering pins. These pins minimize the offset between the mold halves and thus ensure a precise cast part. [0082] Some structures known from metal casting molds may be provided directly on the printed part. Thus, centering elements ( 603 ) may be implemented, and labyrinth seals ( 502 ) may be mounted for a better sealing action between the mold halves. [0083] The reinforcement is inserted into the mold cavity ( 402 ) before the molds are closed. It is expediently held at a distance relative to the mold with the aid of plastic or concrete supports. In this state, empty conduits may also be inserted into the mold for later introduction of electric lines or other media. [0084] The assembly of the molds may be facilitated by bores ( 503 ) in the molds. Bolts, which apply the compressive forces onto critical mold areas in a targeted manner, may be guided through these bores. Additional plates may also be screwed on, which reinforce the mold against the casting forces. [0085] Casting takes place through mounted sprues ( 403 ) or material shafts. Depending on the technique and casting material used, additional ventilation bores ( 602 ) may also be introduced. If a vibrator is to be inserted after casting to compress the casting material, an access is provided in the mold. Mold parts (e.g. 601 ), which are able to float, due to the pressure of the casting material, must be prevented from changing position, e.g. by being weighted down. [0086] After the casting process, the part rests for up to several days, depending on the binding time of the casting material. The demolding process then takes place. [0087] Due to the low strength of the seal, the latter is easily removed from the pores of the mold during breakout (see FIG. 8 ). This process may be assisted by heating the mold together with the cast part. As a result of the low separating forces, even delicate cast parts may be safely broken out of the mold. [0088] If a single-use mold is used, the mold may be pre-damaged by hitting it with a hammer in a targeted manner. Depending on the wall thickness of the mold, the actual separation process is carried out with the aid of a putty knife or another flat tool. The mold may also be separated from the cast body by means of sand blasting. The selection of the blasting material and the pressure must be adapted according to the hardness of the casting material, so that the casting material is not damaged. [0089] The multiple-use mold is preferably placed in a furnace before breakout and heated overnight to a temperature of, for example, 60° C. Air circulation should be avoided to prevent drying out if concrete is used as the casting material. [0090] After the furnace process, the bond between the mold and cast part is stressed by tightening the bolts on the ejectors. The mold then usually opens with the aid of slight vibrations or hammer blows. [0091] After the casting process, the sealing medium ( 801 ) must be removed from the cast part ( 800 ). If grease is used, soaps and washing pastes for cleaning oils and greases are helpful. Hand washing paste that includes cleansing particles is particularly preferred in this case. [0092] After casting, the parts are further processed as in the case of conventional production methods. The usual methods such as grinding or sand blasting are used for surface modification. LIST OF REFERENCE NUMERALS [0093] 100 Print head [0094] 101 Coater [0095] 102 Building platform [0096] 103 Component [0097] 104 Build container [0098] 105 Print head path [0099] 106 Coater path [0100] 107 Powder layers [0101] 108 Direction of building platform movement\ [0102] 109 Dosed droplets [0103] 110 Powder roll [0104] 111 Build space boundary [0105] 112 Coater gap [0106] 113 Coater stock [0107] 114 Powder Cake [0108] 200 Simple cast part [0109] 300 Complex cast part, sink [0110] 301 Bowl-shaped sink area [0111] 302 Hole for faucet [0112] 303 Hole for drain [0113] 400 Casting mold, top box [0114] 401 Casting mold, bottom box [0115] 402 Cavity for casting material [0116] 403 Sprue [0117] 500 Nut [0118] 501 Bolt [0119] 502 Labyrinth seal [0120] 503 Bore for assembly bolts [0121] 600 Sink mold, bottom box [0122] 601 Sink mold, top box [0123] 602 Ventilation bores [0124] 603 Mold centering element and contact point [0125] 604 Mold core for drain [0126] 605 Mold core for faucet [0127] 606 Mold cores for wall mounting [0128] 700 Particle [0129] 701 Geometric mold boundary [0130] 702 Particle of the black wash [0131] 703 Seal [0132] 800 Cast part [0133] 801 Drawn-out seal
The invention relates to a casting mold, in particular for use in cold casting methods, which is produced with the aid of a powder-based layering method, the final casting mold having a treated surface.
1
FIELD OF THE INVENTION The invention relates to a method for producing a filament yarn with alternating S- and Z-twists, in which at least one yarn is moved between two spaced apart twisting stops arranged at a distance from each other, and the yarn receives thereby through at least one false twisting unit of the clamping type arranged between the twisting stops alternately S- and Z-twists which are fixed by means of a fixing unit which is interconnected downstream of the false twisting unit in yarn advancing direction. BACKGROUND OF THE INVENTION In such a method known from the DE 39 31 110 C2, the twisting stops are formed by two stationarily arranged delivery mechanisms, of which one is arranged upstream of the false twisting unit or units, and the other one downstream of the fixing unit, which is designed either as a heating device or as an air-circulating device. The alternating formation of the S- and Z-twists is carried out in a predetermined cycle by switching on and off the clamping action of the false twisting unit. Since, however, the second twisting stop is arranged downstream of the fixing unit in yarn advancing direction, the S- and Z-twists earlier applied to the yarn are, depending on the twisting direction, partially again untwisted and partially yet more tightly twisted in the yarn section extending downstream of the false twisting unit. Thus it is not possible in this manner to produce a yarn which has reproducible alternately defined S- and Z-twists. Furthermore nontwisted sections with a lesser S- or Z-twist are each created between the sections with S-twist and the sections with Z-twist. SUMMARY OF THE INVENTION The basic purpose of the invention is therefore to provide a method for producing a filament yarn with alternating S- and Z-twists, with which in a simple, economical and reproducible manner a filament yarn can be produced which has defined S- and Z-twists per unit of length and therebetween as much as possible no nontwisted or little twisted sections. This is attained according to the invention by the twisting stop provided in yarn advancing direction downstream of the false twisting unit being moved synchronously with the yarn and being held in an engagement with the yarn stopping the twisting until at least the twisting inversion point in the yarn is fixed, and by at least one further twisting stop, following the aforementioned moved twisting stop at a distance, entering into an engagement with the yarn stopping the twisting, and advancing together with same before the yarn is twisted in an opposite direction by the false twisting unit. Thus the invention is based on the thinking to grasp the yarn directly behind the false twisting unit by twisting stops successive in timely and spacial intervals, and to then advance the twisting stops synchronously together with the yarn. A twisting stop has the purpose to prevent a continuation of a twist applied to the yarn into a yarn section lying upstream of or downstream of the twisting stop. Clamping devices are primarily used as twisting stops in the present case, however, a twisting stop can also be designed as a guide edge or through clamping in a delivery mechanism. Yarn sections are in the inventive method each temporarily “fixed” between two spaced twisting stops which follow each other until the final fixation by means of the fixing unit takes place. The yarn sections extending fixed between two twisting stops have either a S- or Z-twist with a specific twist, whereby the term “twist” means according to DIN 60900, Part 2, the number of twists of a single yarn per/m. The specific twist of a section of yarn clamped between two adjacent twisting stops is not influenced or changed by the twists applied to the following yarn sections because the false wire is constructed always only up to the twisting stop closest to the false twisting unit. In this manner also nontwisted sections between the yarn sections with S- or Z-twist are avoided. The inventive method can be continuously carried out and enables the production of a filament yarn with alternating S- and Z-twists. The filament yarn can be produced out of a yarn component, namely a bunch of filaments, and is fixed during the production process following the false twisting unit, which is done by thermofixation. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be discussed hereinafter in greater detail in connection with the exemplary embodiments illustrated in the drawing, in which: FIG. 1 schematically illustrates the structure of the finished filament yarn, FIG. 2 schematically illustrates the operating sequence for the method, FIG. 3 illustrates the relationship between the minimal distance of the movable twisting stops from the false twisting unit under the theoretical twist distribution, FIGS. 4 a to 4 c illustrate the operating principle of two series-connected false twisting units in a first embodiment, FIGS. 4 d to 4 f illustrate the operating principle of a second embodiment, FIGS. 5 to 7 schematically illustrate various movable twisting stop devices, FIG. 8 is a view in direction VIII of FIG. 7 . DETAILED DESCRIPTION FIG. 1 schematically illustrates the structure of the finished filament yarn. Same has alternating yarn sections 1 a with S-twists and yarn sections 1 b with Z-twists. The twisting inversion points 2 , the expansion of which in longitudinal direction of the yarn can be kept very small with the inventive method, each lie between two yarn sections 1 a, 1 b with opposite twists. The lengths of the yarn sections 1 a , 1 b can vary. Smooth and textured multi-filament yarns, preferably in a titer range of between 17 and 330 dtex, are supposed to be utilized as feed materials. FIG. 2 schematically illustrates the operating sequence for the method. The yarn 1 ′ is moved from A to B in a yarn advancing direction C by means of the delivery mechanism 6 , and leaves the delivery mechanism 6 as a finished filament yarn 1 with alternating S- and Z-twists, as it is illustrated in FIG. 1. A first twisting stop 7 is arranged stationarily and can advantageously be designed as a delivery mechanism or as a yarn tensioning device. A false twisting unit 8 is arranged at a distance L 0 downstream of the stationary twisting stop 7 , with which false twisting unit it is possible to subject the yarn 1 ′ successively to alternating S-twists and Z-twists. The detailed design of such false twisting units 8 will be discussed later on in connection with FIGS. 4 a to 4 f . A twisting stop device 9 with several twisting stops 3 movable in the yarn advancing direction C is provided behind the false twisting unit 8 . Each twisting stop 3 is formed by two cooperating clamping jaws 3 a , 3 b , whereby these clamping jaws 3 a , 3 b are supposed to have an as small as possible expansion in the yarn advancing direction C, and are therefore advantageously designed like a blade. It is thus possible to reduce the length expansion of the twisting inversion point 2 to a minimum so that in the finished textile surface these inversion points 2 do not appear as areas of error. The clamping jaws 3 a, 3 b are arranged on continuously driven belts 10 a , 10 b , with which they each can be returned to the false twisting unit 8 . Furthermore the clamping jaws 3 a , 3 b can in this manner be turned on and off. In the area lying between the belts 10 a and 10 b , opposing pairs of clamping jaws 3 a , 3 b are pressed against one another with the inter positioning of the yarn 1 ′ to form then a twisting stop 3 movable in the yarn advancing direction C. The movable twisting stops 3 are spaced apart at a distance L 2 . The twisting stops 3 are moved through a fixing unit 11 , which consists of a heating zone 4 and a downstream oriented cooling zone 5 . The spaced apart distance L 2 of the twisting stop 3 is thereby less than the length L 3 of the fixing unit 11 . It is assured in this manner that the twists alternately oppositely applied to the yarn 1 ′ and temporarily fixed between two twisting stops 3 are thermally fixed when the finished filament yarn 1 leaves the fixing unit 11 . In order for the method to operate as effectively as possible, the twisting stops 3 should engage the yarn 1 ′ to stop the twisting as close as possible to the false twisting unit 8 , and should then be advanced synchronously with the yarn 1 ′. With each new engagement of the yarn by a twisting stop it is possible to change the direction of the twist applications through the false twisting unit 8 . Yarn sections 1 a with S-twist and yarn sections 1 b with Z-twist are alternately temporarily “fixed” between two twisting stop devices, and the yarn 1 ′ is moved in a twisted state initially through the heating zone 4 and then through the cooling zone 5 . Only after the yarn has been cooled off to below a specified temperature, the clamping is cancelled during an exit from the cooling zone 5 . Because of the varying distance L 0 between the stationary twisting stop 7 and the false twisting unit 8 on the one hand and the distance L 1 between the false twisting unit 8 and the movable twisting stop 3 closest to it on the other hand, varying twist heights are created, namely twists per unit of length, in front of and after the false twisting unit 8 . However, only the portion of the twists which lie between the false twisting unit 8 and the nearest moved twisting stop is fixed in the production process. The yarn is theoretically only tightly untwisted and tightly twisted in the area between the twisting stop 7 and the false twisting unit 8 . The false twist is thus divided into two opposite true twists, of which in each case only the twist downstream of the false twisting unit is fixed. In order for this twist to no longer be influenced by the following reversal of the twisting direction, this twisting direction is supposed to be reversed only when the following twisting stop engages the yarn 1 ′. The respective next twisting stop is hereby supposed to be guided close to the false twisting unit 8 in order to keep the distance L 1 as small as possible. Namely, the yarn section in the area L 1 must during a reversal of the twisting direction be first again untwisted and twisted in the opposite direction. The shorter the distance at the start of the reversal of the twisting direction, the more effectively operates the method. This can be recognized by looking at FIG. 3, which shows the theoretical influence of the distances L 0 and L 1 on the twist height upstream of and downstream of the false twisting unit 8 . The times for the engagements of the movable twisting stops are indicated by the reference 3 ′. FIG. 3 illustrates that a large relationship of L 0 /L 1 has a positive effect, and that the minimal distance L 1 between the respective twisting stop 3 which engage the yarn 1 and the twisting unit 8 should be as small as possible. The changing twisting direction of the yarn can be realized both by one false twisting unit with changing twisting direction and also by two false twisting units which are constantly driven in opposite twisting directions, and which can be alternately interconnected. The use of two false twisting units, which are driven in different twisting directions and the active surfaces of which are interconnected, is advantageous. The masses, which are to be accelerated, are in this manner kept very small since the respective interconnection can occur through a movement of the yarn or through a deflection of the active areas. False twisting units 8 , 8 ′ or 8 a, 8 ′ a of the clamping type are illustrated in FIGS. 4 a to 4 f. In the exemplary embodiment illustrated in FIGS. 4 a to 4 c, each of the false twisting units 8 , 8 a has two crossing, continuous belts 12 , 12 ′, at the crossing point of which the yarn 1 ′ can be clamped in order to create the twists. The belts 12 of the first false twisting unit 8 are, for example, driven in such a manner that they can give the yarn downstream, namely in yarn advancing direction downstream of the false twisting unit a S-twist, whereas the belts 12 ′ of the second false twisting unit 8 ′ can give the yarn downstream of the false twisting unit 8 ′ a Z-twist. Each of the two false twisting units 8 , 8 ′ has furthermore two pressure rollers 13 , 13 ′, respectively, with the help of which the active areas 12 a, 12 ′ a of the belts 12 , 12 ′, respectively, which are usually spaced from the yarn 1 ′, can be alternately moved into operating position, as this is illustrated in FIGS. 4 b and 4 c . The belts 12 , 12 ′ of the two respective false twisting units 8 , 8 ′ are continuously driven in the twisting directions indicated by arrows. When according to FIG. 4 b the pressure rollers 13 press the active areas 12 a against the yarn 1 ′, the yarn receives S-twists downstream when the second false twisting unit 8 ′ becomes inactive. In order to give the yarn Z-twists downstream, the pressure rollers 13 of the first false twisting unit 8 are according to FIG. 4 c moved away from one another and the pressure rollers 13 ′ of the second false twisting unit 8 ′ press the active areas 12 ′ a against the yarn 1 ′. By deflecting the active areas 12 a, 12 ′ a of the belts 12 , 12 ′ perpendicular to their direction of movement, very quick switching operations can be realized since, due to the geometry, only very small forces must be applied and only short paths of movement must be covered. The false twisting unit, which is not in the operating position, does not hinder the expansion of the twists in the yarn 1 ′ since their active areas 12 a or 12 a ′ are each spaced from the yarn 1 ′. Each of the two false twisting units 8 a, 8 ′ a consist in the exemplary embodiment illustrated in FIGS. 4 d to 4 f of two continuously driven disks 14 , 14 ′, the axial faces of which form the active areas 15 , 15 ′, between which the yarn 1 ′ can be clamped. This is accomplished by the two disks 14 or 14 ′ axially approaching one another. Thus it is possible, for example according to FIG. 4 a, to give the yarn 1 ′ downstream, namely in yarn advancing direction C the yarn section extending downstream of the false twisting unit 8 a, Z-twists when the active areas 15 of the disks 14 are pressed against the yarn 1 ′ and the active areas 15 ′ of the second false twisting unit 8 a ′ are spaced from the yarn 1 ′ and are thus inactive. The active areas 15 ′ are in the position of the false twisting units illustrated in FIG. 4 f pressed against the yarn 1 ′ and the yarn thus receives downstream S-twists and the first false twisting unit 8 a is inactive. Various twisting stop devices are illustrated in FIGS. 5 to 7 . The twisting stop device 9 illustrated in FIG. 5 corresponds essentially to the exemplary embodiment illustrated in FIG. 2 so that an explanation reference can be made to the description of FIG. 2 . The evenly driven continuous driving means 10 a , 10 b , can, for example, be belts or chains. Several rigid clamping elements 17 are, in the twisting stop device 9 ′ illustrated in FIG. 6, arranged spaced from one another on the continuous driving means 16 . A movable clamping element 18 , which is pivotal about an axis 19 , is associated with each rigid clamping element 17 . When the movable clamping element 18 is pressed against the rigid clamping element 17 , clamping occurs. A control cam 20 can be used to control the movable clamping element 18 . The heating zone is identified by the referenced numeral 4 . Several support arms 21 are provided, in the twisting stop device 9 ″ illustrated in FIG. 7, spaced from one another on a continuous driving means 16 , which support arms each carry one rigid clamping jaw 22 on their free end. Each support arm 21 is associated with a movable slide member 23 having a clamping jaw 23 a. The slide members 23 can be moved relative to the support arms 21 in their longitudinal direction by operation of a control cam 20 or the like, and the movable clamping jaws 23 a can thus each be moved into a clamping position or an opening position. Each clamping jaw pair 22 , 23 a forms one twisting stop. In the exemplary embodiment illustrated in FIGS. 7 and 8, the clamping jaws 22 are arranged on relatively thin support arms 21 and at a greater distance from the driving means 16 . When the clamping jaws 22 , 23 a are in a clamping position and thus in an engagement to stop twisting, they can elastically yield in yarn-advancing direction C and can thus compensate for changes in the length of the yarn, which changes can be created by twisting and shrinkage. When the fixing unit 11 consists of a heating zone 4 and a cooling zone 5 connected thereafter, each yarn section 1 a , 1 b including the inversion points 2 lying therebetween is fixed. If necessary, it is, however, also possible to fix only the inversion points 2 , which can, for example, be accomplished by heated clamping jaws.
A method for producing a filament yarn with alternating S- and Z-twists. The yarn is moved between two twisting stops and submitted alternatively to S- and Z-twisting by at least one false twisting unit. The twists are fixed in a fixing unit situated downstream from the false twisting unit. The twisting stop downstream of the fixing unit is moved synchronously with the yarn and held in a yarn engagement position to stop the twisting until at least the twisting inversion points is fixed in the yarn. At least one other twisting stop oriented at a distance from the above mentioned moving twisting stop is engaged with the yarn in a way to stop the twisting and is moved along with the yarn before said yarn is submitted to an opposite twisting by the false twisting unit.
3
RELATED APPLICATION [0001] This application claims the benefit of co-pending provisional patent application serial No. 60/384,211, filed May 30, 2002. BACKGROUND OF THE INVENTION [0002] This invention relates generally to hardware for securing bundled elongate articles, such as wires, cables, hoses, tubing, fiber optics, conduits, vines, etc., to a supporting structure. More particularly, the invention relates to a mounting element, engaged by a stud, bolt, screw, rivet, etc., extending from the supporting structure or its facing surface. [0003] Flexible ties are widely used to secure elongate items, such as wires, cables, hoses and tubes, into compact secure bundles. Typically, such ties include a head and a flexible strap which terminates in a tail. In use, the tie is looped around the elongate item and the tail is inserted through the head of a mount, such as a saddle mount. The tail is then pulled tight to pull the strap around the articles, and thereby secure the articles into a compact, neat bundle. A pawl mechanism within the head secures the strap against withdrawal. [0004] In many applications, it is sufficient merely to secure the items into a bundle. Such applications might include, for example, stationary electronic equipment that remains in one place and is subject to little or no vibration in use. In other applications, it is necessary or desirable not only to secure the items into a bundle, but to secure the resulting bundle to a supporting chassis or framework as well. Such applications are also common, for example, in cars, trucks, airplanes, ships, boats and other vehicles where the bundle is likely to be subjected to severe jostling and vibration. In other applications (e.g. buildings), where vibration might not be an important consideration, it is still desirable to secure cables, hoses, tubes, etc., to a fixed structure. [0005] Flexible ties, in and of themselves, are not readily mounted to a supporting structure without the use of additional mounting structures or, in the present case, saddle mounts. Various types of mounts have been proposed. Such mounts are used in conjunction with flexible cable ties and provide an anchor to which the cable tie can be secured in use. Generally, mounting structures can either be entirely formed with a cable tie to create a one-piece structure or they can comprise an element wholly separate from the cable tie. Integrally formed mounting structures result in a one-piece tie that simultaneously secures the wire or similar article into a bundle and allows for securing the resulting bundle to a supporting structure. SUMMARY OF THE INVENTION [0006] The present invention provides an improved mount for securing a flexible tie encircling and bundling an elongate article to a supporting surface. The mount comprises a unitary member including an integrally formed base portion and support portion extending outwardly away from the base portion, and wherein the outwardly extending portion includes an aperture for receiving a stud or fastener engagable with a supporting structure, such as a frame rail or similar element. The rear facing surface of the mount may further include a rearwardly extending protrusion for direct engagement with the supporting structure to act as a deterrent for pivoting movement of the mount with respect to the supporting stud. [0007] The present mount also includes a transverse aperture for receiving and supporting a portion of a flexible tie adapted to bundle elongate items, such as wires, cables, hoses, tubing, fiber optics, conduits, vines, etc. The bundling is completed by dimensioning the tie with a headed end and a trailing end, and wherein the headed end includes an aperture with a pawl or the like for receiving the trailing end and permitting the trailing end to be pulled tightly therethrough as it encircles and bundles the hardware to be secured. [0008] Alternatively, the present invention may include a metal bushing insert provided in the aperture for receiving the stud or fastener. The metal bushing insert is provided to supply additional reinforcement and therefore allow additional torque to be applied during securement to a supporting structure. The metal bushing is preferably formed from a low alloy steel or from a powdered metallurgy process. [0009] It is therefore the principle object of the present invention to provide a securing means for minimizing the pivotal movement of an apertured mount as it is anchored on a stud member, such as a screw, a bolt and nut combination or a headed nail protruding from a supporting structure. [0010] It is a further object of this invention to provide an apertured mount including a base portion defining an arched under surface and a transverse opening and including a notched out area intermediate the ends of said under surface. This configuration permits alternative application of the mount for use with bundled elongate objects having relatively different circumferences, the larger circumference being accommodated by a major portion of the arched under surface, whereas a relatively smaller diameter bundle being accommodated by the intermediate area and having its bundle tie through an integrally formed and cooperating locking pawl. [0011] In an alternative embodiment the mount includes a reinforcing insert located in the aperture. The insert provides additional support and strength to the mount for receiving and supporting a stud or fastener engagable with a supporting structure. The insert preferably includes an inner surface for supporting contact with a fastener, and an outer surface for supporting engagement with the surface of the aperture. Further, the alternative embodiment mount may include a supporting surface DESCRIPTION OF THE DRAWINGS [0012] The invention, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, wherein like reference numerals identify like elements, and wherein: [0013] [0013]FIG. 1 is a perspective view of the mount embodying the various features of this invention. [0014] [0014]FIG. 2 is a rearward perspective view taken from a point below the mount as illustrated in the view of FIG. 1. [0015] [0015]FIG. 3 is a front facing elevational view of the mount of this invention. [0016] [0016]FIG. 4 a is a cross sectional view of the mount taken along lines 4 - 4 of FIG. 3, and as further depicted in anchoring relationship with a supporting structure, such as a vehicle chassis frame, or the like. [0017] [0017]FIG. 4 b is a cross sectional view of an alternate mount taken along lines 4 - 4 of FIG. 3, and as further depicted in an alternate anchoring relationship with a supporting structure, such as a wall or a vehicle chassis frame, or the like. [0018] [0018]FIG. 5 is a cross sectional view taken along lines 5 - 5 of FIG. 4 b , and further indicating a relationship, in phantom fragmentary view, of a mount with flexible strap and further shown in phantom in connection with bundling a plurality of elongate objects. [0019] [0019]FIG. 6 is a perspective view of an alternative embodiment of this invention. [0020] [0020]FIG. 7 is a plan view of the mount of the invention as disclosed in FIG. 6. [0021] [0021]FIG. 8 a is a cross-sectional view taken along lines 8 a - 8 a of FIG. 7 and further disclosing, in phantom view a bundle of elongated objects of relatively large diameter seated adjacent the mount. [0022] [0022]FIG. 8 b is a cross-sectional view taken along lines 8 b - 8 b of FIG. 7 and illustrating a bundle of tied elongated objects of lesser diameter which may be held in place by the alternative constructive mount of this invention. [0023] [0023]FIG. 9 is a perspective view of an alternative embodiment of this invention showing a metal bushing insert. [0024] [0024]FIG. 10 is a top plan view of the mount shown in FIG. 9. [0025] [0025]FIG. 11 is a bottom plan view of the mount shown in FIGS. 9 and 10. [0026] [0026]FIG. 12 is a cross sectional view taken along lines 12 - 12 of FIG. 10 and as further depicted in anchoring relationship with a supporting structure with flexible strap in connection with bundling an elongate object shown in phantom. [0027] [0027]FIG. 13 is an exploded view of an alternative embodiment mount similar to that shown in FIG. 9, but showing an alternative metal bushing insert. [0028] [0028]FIG. 14 is a cross sectional view taken along lines 14 - 14 of FIG. 13 and showing the alternative bushing insert in place in the mount. [0029] [0029]FIG. 15 is an exploded view similar to that of FIG. 13 but showing another alternative embodiment metal bushing insert. [0030] [0030]FIG. 16 is a cross sectional view taken along lines 16 - 16 of FIG. 15 and showing the metal bushing insert in place in the mount. [0031] [0031]FIG. 17 is an exploded view similar to that of FIGS. 13 and 15 but showing another alternative embodiment metal bushing insert. [0032] [0032]FIG. 18 is a cross sectional view taken along lines 18 - 18 of FIG. 17 and showing the metal bushing insert in place in the mount. [0033] [0033]FIG. 19 is an exploded view similar to that of FIGS. 13, 15 and 17 but showing yet another alternative embodiment metal bushing insert. [0034] [0034]FIG. 20 is a cross sectional view taken along lines 20 - 20 of FIG. 19 and showing the metal bushing insert in place in the mount. [0035] [0035]FIG. 21 is an exploded view similar to that of FIGS. 13, 15, 17 , and 19 but showing still another alternative embodiment metal bushing insert. [0036] [0036]FIG. 22 is a cross sectional view taken along lines 22 - 22 of FIG. 21 and showing the metal bushing insert in place in the mount. DETAILED DESCRIPTION [0037] Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention that may be embodied in other specific structure. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. [0038] A flexible tie mounting system, shown generally by the reference character 10 , embodying various features of the present concept, is shown in particular, in connection with FIG. 5. As illustrated, the system 10 is used to secure elongate elements or items, such as adjacent strands of wire, conduit or fiber optics strands 12 (herein shown in phantom, encased in an outer tubular conduit 13 ), to a supporting structure 34 by means of an outwardly projecting mounting element 14 having a head 15 and a threaded shaft 16 (see phantom lines in FIGS. 4 a and 4 b ). The shaft 16 with head 15 and nut 18 may be a conventional threaded bolt and nut, a screw or a stud (not shown). For illustrative purposes, the supporting structure 34 may also be the frame rail 17 (see FIG. 4 a ) of a truck or similar vehicle subject to jostling as the vehicle moves along bumpy roads or subjected to other rough usage. It will be appreciated that the system 10 may be used in other applications, and can be used to mount other tie bundled items to any form of a supporting structure 34 utilizing a mounting element, such as a stud, bolt, screw, threaded rod, rivet, nail, etc. [0039] A portion of a flexible tie 18 , as shown in phantom in FIG. 5, has been passed through a transverse aperture 20 of the mount 22 of the present invention. The flexible tie 18 is supported by the inner surface 23 of a wall member 24 . The arched exterior surface 25 of the wall member 24 supports the bundled element 12 , 13 . [0040] With particular attention to the mount 22 , as shown in FIGS. 4 a and 4 b , it will be noted that the mount 22 is provided with an integral base portion 26 having an upstanding, laterally extending support portion 28 . The upwardly extending portion 28 includes an aperture 30 arranged to receive the mounting element 14 illustrated herein to be in the form of a threaded bolt having the head 15 and threaded shaft 16 engageable with a threaded opening in the supporting structure 34 . Again, the threaded bolt 14 is shown for illustrative purposes only. This projecting mounting element 16 , may also take the form of a bolt, screw, threaded rod, rivet, mounting stud, etc. or similar item. [0041] In one embodiment, the mount 22 further includes, at its rear surface 36 protrusions 38 a , 38 b and 38 c (see FIG. 2 and FIG. 4 a ). The protrusions 38 a , 38 b and 38 c are each laterally spaced from the aperture 30 . The protrusions 38 a and 38 c take the form of a ledge extending outwardly from the inner surface 36 of the mount 22 . These ledges, or flanged protrusions 38 a and 38 c extend across the mount 22 to provide a surface for engaging the supporting structure 34 , as does the generally oval shaped protrusion 38 b surrounding the aperture 30 . The protrusions 38 a and/or 38 b and/or 38 c act to provide a means for minimizing rotation of the mount 22 around its aperture 30 when supported by the mounting element 14 . The external dimensions of the protrusions 38 a , 38 b and 38 c are relatively thin when compared to the inner facing surface 36 of the mount 22 . This relationship permits tight clamping engagement of the mount 22 with the supporting structure 34 . When the head 15 of the mounting element 14 is tightened to engage and urge the mount 22 towards the supporting structure 34 . In the case of a relatively soft wooden supporting structure 34 , the protrusions 38 a and 38 b may actually penetrate the surface of the wooden wall 34 . With a metal frame rail 17 , the protrusions 38 a and 38 b fit within a mating opening to minimize rotation of the mount 22 around the supporting stud or other mounting element 14 . Such action will act to stabilize the bundled elements 12 relative to the mounting surface 17 . [0042] An alternate embodiment of the invention 32 is shown in FIG. 4 b . In this embodiment, the protrusion 38 b has been removed. The mount 32 is again secured to the mounting surface 34 , but relies on the frictional interface between the mount 32 and surface 34 for rotational stability. [0043] The present invention also contemplates the use of only one protrusion, either 38 a or 38 b or 38 c , so long as it is spaced from the aperture 30 . This design, when dimensioned properly, will provide a lever arm adding to the torque required to pivotally move the mount 22 relative to the wall 34 of frame rail 17 . [0044] It will be noted that the rearwardly extending protrusion 38 b includes a minor axis “a-a” and a major axis “b-b” (see FIG. 2). The major axis “b-b” of the oval protrusion 38 b lies substantially parallel with the lower surface of the ledge protrusion 38 a to provide additional interference with the ledge 38 a when the mounting element 16 has been tightened with its head 15 tightly engaging the front surface of the mounting 22 . This arrangement will provide a secure anchoring surface with respect to a supporting structure 34 as shown in FIG. 4. [0045] Although the preferred embodiment utilizes a generally oval shaped enclosed protrusion surrounding the aperture 30 it will be apparent that protrusions of other configurations may be substituted and remain within the province of the present invention. [0046] With particular attention to FIGS. 2 and 5, it will be observed that the ledge or flanged portions 38 a and 38 c also provide an extension of the wall member 24 of the mount 22 , with its lower surface 25 being curved or arched to provide a contacting surface for further support of the bundled element 12 . [0047] As shown in FIGS. 1 and 3, the front face of the mount 22 is preferably molded with a series of re-entrant openings 40 separated by webs 41 . The openings 40 are designed to reduce the amount of resin needed for injection molding, without sacrificing strength of the integrally molded mount 22 . [0048] Another embodiment of the present invention will next be explained with respect to the views of FIGS. 6 - 22 , inclusive. With particular attention to FIG. 6, it will be noted that a mount 22 a of similar construction to the mount 22 has been provided. There is the opening 30 arranged to accommodate a mounting element such as a stud 14 shown in phantom in the views of FIGS. 8 a and 8 b . As previously described, the stud is intended to engage a threaded opening in a supporting structure, such as a wall 34 . [0049] As will be noted, the present embodiment includes a supporting surface 45 of a relatively expanded arcuate dimension suitable for supporting a relatively large bundle of tie bundled objects 12 as shown in FIG. 8 a . The surface 45 extends at opposite ends to define outwardly projecting flanged areas 38 a and 38 c , and notched out areas 48 . The notched out areas 48 , as shown in FIG. 8 b , will accommodate a bundle of relatively small diameter when compared with the relatively larger bundle 12 of FIG. 8 a . The tie 18 of standard width may be used to bundle either of the buckled objects 12 , whether of enlarged diameter or of the smaller diameter shown in FIG. 8 b . The flexible tie 18 will be pulled through its locking means 19 to the desired diameter and will be latched in place by an inner pawl (not shown) as is well known in the art. Proper support will be provided by this embodiment, no matter the diametrical size of the bundle to be supported by the mount 22 a. [0050] As shown in FIGS. 9 - 22 , an insert 50 may be molded or placed within the opening 30 . In my preferred embodiment, the insert 50 is formed from a metallic material such as low alloy steel or formed from a powder metallurgy process. The insert provides the benefit of allowing the mounting element 14 to be tightened to a predetermined torque that is higher than the torque permissible without the insert 50 . In other words, without insert 50 the mount 22 a may deform, collapse or fail if the mounting element torque exceeded a certain level. Including the insert 50 allows the torque to be sufficiently greater without causing damage to the mount 22 a. [0051] As best shown in FIG. 12, the insert 50 may have an annular shape including substantially smooth outer walls 52 . The insert may be either press fit into the mount 22 a or may be integrally molded therein. As shown in FIGS. 13 and 14, the insert 50 may include a secondary annular protrusion 54 to retain the insert within the mount 22 a . As shown in FIGS. 15 and 16, the inset may include laterally spaced, triangular protrusions 56 along the outer surface of the insert 50 . As shown in FIGS. 17 and 18, the insert may include laterally spaced, semi-cylindrical protrusions 58 along the outer surface of the insert 50 . As shown in FIGS. 19 and 20, the insert may include a secondary annular protrusion having a knurl 60 formed thereon. As shown in FIGS. 21 and 22, the insert may include simply a knurl 62 formed along the full height of the outer surface of the insert 50 . [0052] The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.
A mount for securing a flexible tie encircling and bundling an elongate article or articles to a supporting surface. The unitary mount includes a base portion and a support portion. Structures are provided for non-pivotal attachment to a mounting surface. Structure is also provided in an alternate embodiment for permitting the mount to support tied bundles of various diameters. A reinforcing insert may be provided within the base portion.
5
TECHNICAL FIELD The present invention relates generally to a method and apparatus for the collection of contaminated ground water, and is particularly directed to the collection of contaminated ground water which may be intercepted by an existing storm sewer system and the segregation of the contaminated ground water from storm water flowing through the existing storm sewer system. The invention will be specifically disclosed in connection with the formation of a ground water collection channel substantially within an existing storm sewer pipe in conjunction with an in situ formed lining disposed within the existing storm sewer pipe to form a segregated storm sewer channel/flow passageway. BACKGROUND OF THE INVENTION Contaminated ground water can present several problems to past or present property owners or lessees. In some cases, it is the responsibility of the property owner to collect and treat the contaminated ground water to prevent it from migrating to adjacent areas. In instances where existing underground storm sewer pipes are located or pass through saturated areas of contaminated ground water, the contaminated ground water may infiltrate the storm sewer pipe through the cracks and joints. The infiltrated contaminated ground water will, by itself or mixed with storm water, flow to the outfall of the storm sewer system, bringing the contaminated ground water to the surface. There are federal, state, and local regulations relating to required treatment of such contaminated ground water. The concentration of contaminants in infiltrated ground water flowing through and out of storm sewer pipes decreases when it mixes with the relatively higher volume of storm water flowing periodically through the storm sewer pipe. While dilution of the contaminants may be somewhat beneficial, such mixing creates relatively large volumes of contaminated water which must be treated, requiring a substantial increase in the capacity of any treatment facility. Thus, it is undesirable to allow the mixing of contaminated ground water with storm water. Beside completely removing and replacing the preexisting storm sewer pipe, one way of segregating contaminated ground water from storm water is to line the preexisting storm water pipe with an impermeable lining. Pre-formed slip linings are well known in the art. In situ formed linings are also known, such as described in U.S. Pat. No. 4,637,754, which is incorporated herein by reference, and allow the formation of an impermeable storm water channel/flow passageway with a minimal impact on the effective flow area. Neither of these alone provide for the collection of ground water. As mentioned above, segregation of contaminated ground water from storm water frequently must be accompanied by collection and treatment of the contaminated ground water. Various methods are known in the prior art for collection of ground water. For example, horizontal or vertical wells may be bored into the saturated area and the contaminated ground water withdrawn and treated. However, horizontal boring is expensive and inaccurate. The effectiveness of vertical boring depends upon the nature of the aquifer and the soil. For compact soil conditions, numerous and closely spaced vertical wells are required, which is expensive. Another alternative in the prior art is trenching to provide access to the contaminated ground water, as well as the use of a ground water collecting pipe buried parallel to the existing storm sewer lines. Most of these methods are relatively expensive, and are impractical when the contaminated ground water and/or existing storm sewer pipe are located underneath existing buildings. Thus, them is a need for an economical way to collect contaminated ground water and maintain it segregated from storm water. SUMMARY OF THE INVENTION Accordingly, it is a primary object of the present invention to provide a method and apparatus for collecting contaminated ground water and conveying it, segregated from storm water, to a location for treatment. It is another object of the present invention to provide a method and structure for utilizing existing storm sewer pipes to collect, convey and segregate contaminated ground water. It is yet another object of the present invention to provide a method and structure for collecting and segregating ground water which improves or has minimal impact on the capacity of the existing storm water conveyance. A still further object of the present invention is to provide a method and structure for collecting and segregating ground water which minimizes the disruption of the site and the need for demolition and reconstruction of existing facilities. Yet another object of the present invention is to facilitate permitting for effluent discharge or storm water discharge by improving effluent quality of the existing outflow. Another object of the present invention is to reduce the potential for discharge of contaminated ground water into the environment. Additional objects, advantages and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims. To achieve the foregoing and other objects, and in accordance with the purposes of the present invention as described below, a method and system is provided for forming a ground water collection channel within existing storm sewer pipes, lining the pipe to segregate the contaminated ground water from storm water, and conveying the contaminated ground water to a treatment facility. In accordance with another aspect of the present invention, a ground water passageway and a storm water passageway are defined within an existing under ground pipe. Still other objects of the present invention will become apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration, of one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive. BRIEF DESCRIPTION OF THE DRAWINGS 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: FIG. 1 is a diagrammatic, fragmentary, elevational view of the ground water collection, segregation and conveying system of the present invention. FIG. 2 is a cross-sectional view taken along line 2--2 of FIG. 1. FIG, 3 is an enlarged, fragmentary view of the ground water channel as illustrated in FIG. 2. FIG. 4 is a plan view of the drainage net. FIGS. 4a and 4b are side views of the drainage net taken along lines 4a and 4b, respectively, of FIG. 4. FIG. 5 is a cross-sectional view at a joint taken along line 5--5 of FIG. 1. FIG. 6 is a diagrammatic elevational view of an existing manhole and storm sewer pipe showing the beginning of the ground water channel. FIG. 7 is a diagrammatic, fragmentary elevational view showing the intersection of laterals into the existing storm sewer system at a manhole. FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 7. FIG. 9 is an enlarged cross-sectional view of the ground water channel shown in FIG. 8. FIG. 10 is a cross-sectional view of the storm water channel/passageway passing through an existing manhole. FIG. 11 is a diagrammatic, plan view of an existing manhole in which the sump is being located. FIG. 12 is a diagrammatic cross-sectional view of the sump taken along line 12--12 of FIG. 11. Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings, FIG. 1 is a diagrammatic, fragmentary view of a ground water collection, segregation and conveying system according to the present invention. Existing storm sewer pipe 2 has been separated into storm water channel/passageway 4 and ground water channel 6 by impermeable lining 8. Ground water channel 6 terminates at sump 10, which is illustrated as being located at the bottom of existing manhole 12. Ground water, as indicated generally by arrows 13, infiltrates exiting pipe 2, and flows through ground water channel 6, as indicated generally by arrows 15, into sump 10 from which it is pumped to a treatment unit as indicated by arrow 14. Treated ground water may be returned from the treatment unit to storm water channel passageway 4 as indicated by arrow 16. Since the ground water is segregated from the storm water flow, as indicated generally by arrows 17, only the volume of ground water flowing into and through ground water channel 6 must be treated. Referring now to FIG. 2, which is a cross-sectional view taken along line 2--2 of FIG. 1, and to FIG. 3, which is an enlarged fragmentary view of ground water channel 6 of FIG. 2, ground water channel 6 is formed along the invert of existing storm sewer pipe 2, between impermeable lining 8 and existing pipe 2. Ground water channel 6 is formed by first drilling or otherwise forming a plurality of spaced apart holes 18 along the length of existing pipe 2, generally at any locations where contaminated ground water is in contact with the outside of existing pipe 2, in order to promote the inward flow/collection of ground water. In the preferred embodiment, based on specific flow calculations, a series of one-inch diameter holes were drilled at approximately 3 foot centers along the invert of pipe 2. More or less core holes may be used, depending upon the specific ground water conditions. High density polyethylene (HDPE) drainage net 20 is disposed along the length of the invert of existing pipe 2. Drainage net 20 is also disposed between lining 8 and pipe 2 adjacent any holes 18, cracks and joints, extending downwardly about the circumference of lining 8 to provide a plurality of flow paths down to ground water channel 6. Drainage net 20, as illustrated in FIG. 4 is a criss-cross mesh of ribs 22a and 22b which define a plurality of openings 22. FIG. 4a is a side view taken along arrow 4a of FIG. 4, while FIG. 4b is a side view taken along arrow 4b of FIG. 4. This configuration reduces the impact of blockages on the flow of water along drainage net 20. Drainage net 20 is available from the Tensar Corporation, Morrow, Ga. 30260. In the preferred embodiment, Tensar's DN-1(NS-1100) net was used. Two side-by-side inverted channels 24, 26 are disposed overlying drainage net 20 along the invert, extending the length of existing pipe 2, secured in place to pipe 2 by a plurality of fasteners 28. In the preferred embodiment, fasteners 28 were TAPCON® Blue Max® self threading masonry anchors from Illinois Tool Works of Itasca, Ill. Each channel includes a respective longitudinal rib 24a and 26a (see FIG. 5) and comprises individual sections which are aligned end to end along the length of the existing pipe 2. Drainage net 20 functions to distribute flow among the available channels more uniformly so as to render the system less susceptible to plugging by debris and deposits. In the preferred embodiment, channels 24 and 26 were PolyLock sections manufactured by SLT North America, Inc. out of HDPE. The PolyLock channels were selected because they are economical, commercially available, and provide a low profile pathway that minimally reduces the effective cross sectional area available for the storm water flow. The PolyLock channels are also chemically and thermally compatible with the process for forming lining 8 in situ, as described below. The size and side-by-side arrangement of the PolyLock channels were selected to provide sufficient capacity for ground water channel 6 to collect and convey the anticipated flow rate of the contaminated ground water. In the specific embodiment described this was calculated to be 20 GPM. Liner 30, made of 60 mil HDPE, is disposed overlying channels 24 and 26. Liner 30 extends the length of existing pipe 2, having a width that extends beyond the lateral edges of drainage net 20. Felt layer 32 is disposed overlying liner 30, running the length of existing pipe 2. Felt layer 32 is substantially coextensive with liner 30. Impermeable lining 8 is then formed in situ within existing pipe 2, substantially in accordance with the teaching of the '754 patent. The installation process of lining 8 consists of inverting a felt tube impregnated with a thermal setting resin into an existing manhole. The tube is then filled with water and allowed to flow the course of the sewer. The weight of the water inverts the tube, turning it inside out and pressing the tube firmly against the inside walls of existing pipe 2. After the tube is inverted through existing pipe 2 to the desired length, the water used for inversion is pumped through a boiler. The hot water causes the thermal set resin to cure within a few hours. After curing, lining 8 is a corrosion resistant, jointless pipe. During this process, impermeable lining 8 is inserted and expanded directly against felt layer 32. Felt layer 32 and liner 30 are used in this particular embodiment to protect the channels 24 and 26 and prevent resin from seeping into the area which will be ground water channel 6. Felt layer 32 is made of the same felt material as lining 8, and functions to absorb excess resin present during installation of lining 8. As illustrated, this method segregates existing pipe 2 into storm water channel/passageway 4 and ground water channel 6. Referring now to FIG. 5, which is a cross-sectional view at joint 34 taken along line 5--5 of FIG. 1, in order to promote the inward flow of ground water, spaced apart holes 18 have been drilled or otherwise formed about the circumference of pipe 2 adjacent joint 34. Prior to installation, appropriate lengths and widths of drainage net 20 and liner 30 are tack welded together for convenience of installation. Drainage net 20 and liner 30 are secured to the inner circumference of existing pipe 2 at joint 34 with fasteners, such as TAPCON® Blue Max® self threading masonry anchors, and washers (not shown), with drainage net 20 disposed between liner 30 and pipe 2. Liner 30, which is wider than drainage net 20, is sealed with butyl rubber caulking to the inner surface of pipe 2 along each edge to prevent excess resin present during the installation of lining 8 from seeping into drainage net 20. Ground water which seeps through joints 34, or which flows through holes 18, flows along drainage net 20 about the outside circumference of lining 8 and liner 30 down to ground water channel 6. In the configuration shown, drainage net 20 under channels 24 and 26 allows an alternate flow path for ground water in the event that one of channels 24 or 26 becomes blocked. In such case, drainage net 20 would allow the ground water to flow therealong into the non-blocked adjacent inverted channel. Although as described in the preferred embodiment, ground water channel 6 is formed through the use of inverted channels 24 and 26, the method of the present invention encompasses any means for establishing the necessary effective flow area for ground water channel 6 outside of lining 8 within existing pipe 2. Ribs 24a and 26a may also be omitted, although they provide rigidity to channels 24 and 26. Throughout the existing storm sewer system, there are typically manholes which form intersections between various segments of existing storm sewer pipes. The bottom of such manholes may be flat or curved. The storm water flow may be redirected. At such junctions, it is necessary to make sure that the ground water channel within one segment of the existing storm sewer pipe is in fluid communication with the ground water channel within a subsequent segment of the existing storm sewer pipe, remaining segregated from the storm water channel/passageway. It is further necessary to breach lining 8 to allow commmingling of storm water discharge from tributary storm sewer pipes. Grouting is necessary to prevent storm water from entering ground water channel 6, and to provide a smooth base to the invert of pipe 2 so as to prevent erosion during high flow and puddling during low flow. FIGS. 6-12 show specific embodiments used for different manhole configurations and conditions. These illustrative FIGS. are not exhaustive with respect to the application of the present invention to manholes and other intersections or pipe configurations. Referring to FIG. 6, an exemplary beginning of ground water channel 6 within existing pipe 2 is diagrammatically illustrated. At the beginning, in order to segregate storm water channel passageway 4 from ground water channel 6, end 6a of ground water channel 6 is sealed by grout 36 which also provides a smooth transition for the storm water flowing into storm water channel/passageway 4. In the preferred embodiment, the grout used was Sika Top-123 high build polymer modified portland cement repair mortar. In the preferred embodiment, a grouting adhesive was used to provide a good surface bonding at each location where grout was placed. In particular, Sika DUR 32 Hi-Mod high strength grouting adhesive was used. Within manhole areas, the upper portion of the lining is removed to allow the collection of storm flow from any lateral storm sewer pipes terminating at the manhole. For example, FIG. 7 is a diagrammatic side fragmentary view of existing pipe 2 intersecting with smaller existing pipe 38 at manhole 40. A portion of lining 8 has been removed leaving edges 8a and 8b. FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 7, illustrating more clearly lining 8 and edges 8a and 8b. In this illustration, existing lateral pipe 42 terminates at manhole 40 at an elevation higher than existing pipe 2. Because of this elevation, edge 8a extends upward from the invert of storm water channel/passageway 4. In order to direct any storm water coming from existing lateral pipe 42 into storm water channel/passageway 4, grout 44 is placed above existing bottom 46 of manhole 40. On the right side of FIG. 8, existing pipe 38 is illustrated as entering manhole 40 at a low elevation, such that edge 8b of lining 8 must be relatively low. In order to direct the flow of storm water into storm water channel/passageway 4, grout 48 is placed following the contour of edge 8b in FIG. 8 as shown. FIG. 9 is an enlarged fragmentary view showing the construction of ground water channel 6 in a typical flat bottom manhole. In such an instance, the existing manhole bottom may not provide a suitable foundation or area of contact to allow lining 8 to encapsulate ground water channel 6 effectively. The presence of storm sewer laterals may exacerbate this situation. In this situation, ground water channel 6 is encapsulated with grout 48 prior to installation of lining 8. Grout 48 is applied as necessary to create a tapered surface from the top of ground water channel 6 to the existing manhole bottom. Grout 48 surrounds channels 24 and 26, establishing the top and edges of ground water channel 6, and also keeps the resin used in setting lining 8 from encroaching into ground water channel 6. Referring now to FIG. 10 there is shown a cross-sectional view of storm water channel/passageway 4 passing through manhole 50 (partially shown), in which a substantial portion of the circular shape is maintained. Grout 52 is used to provide a gradual transition into the upper edges of lining 8. FIG. 11 is a plan view of existing manhole 54 which was adapted to have sump 10 disposed therein. It should be kept in mind that FIG. 11 illustrates a specific manhole embodiment, which for example includes abandoned storm sewer lateral 55, and other manhole configurations exist in which the sump may be located. Existing bottom 56 (see FIG. 12) of manhole 54 is substantially flat. In manhole 54, storm water is directed through an approximate 90° turn by turn vane 60, while segregated ground water channel 6 is routed into sump 10. Referring to FIG. 12, sump 10 is an impermeable container which, in the preferred embodiment, is prefabricated HDPE. Sump 10 is located to receive the discharge of ground water from ground water channel 6. Sump 10 is located at or near the end of the storm sewer system. A plurality of sumps may be used throughout the storm sewer system if necessary, providing a plurality of ground water collection points. In the preferred embodiment a single sump was used. The size (including the aspect ratio, diameter to depth) of sump 10 is dictated by the ground water flow rate, sump pump capacity and the manhole access opening. Sump 10 is located in an existing manhole by forming a suitably sized hole 62 through and below manhole bottom 56. Grout 64 (Sika Top-111) is placed in hole 62, surrounding sump 10. A portion of sump 10 extends above the level of manhole bottom 56 and is enclosed by cover 68, to keep storm water from entering sump. In order to provide for displacement of air within sealed sump 10, vent pipe 70 is disposed through the side wall of sump 10, extending upwardly to a height sufficient to preclude storm water from entering vent pipe 70. The sidewall of sump 10 is sealed where vent pipe 70, as well as where ground water channel 6, enter. Ground water channel 6 and drainage net 20 extend across manhole bottom 56, encapsulated by grout 58 (Sika Top-123). Formed cradle 58a is also made of grout 58, to accommodate construction of turn vane 60, as described below. Alternatively, an HDPE liner may be disposed below channels 24 and 26. HDPE liner 30 and felt layer 32 overlay channels 24 and 26, extending to base 60b of turn vanes 60. Lining 8 overlays felt layer 32, and extends to the upper edge of turn vane 60. Turn vane 60 is constructed of brick and mortar above formed cradle 58a to redirect storm water flow 90° to the down stream lateral. A coating 60a of Sika Top-123 is applied to the brick and mortar to form a substantially smooth surface. Collected ground water is removed from sump 10 by, for example, a submersible pump (not shown) or other appropriate means, and delivered by a pipe (see arrow 14 of FIG. 1) to a treatment unit. An appropriate level sensor, such as a float, may be used to activate the pump as necessary. The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described in order to best illustrate the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
A method and system for collecting ground water segregated from storm water are provided in which an existing storm sewer pipe may be retrofitted by forming a ground water channel and a storm water channel therein. The two channels may be formed by disposing a lining within the existing pipe which segregates the pipe into two distinct flow passageways. A new pipe may also be similarly used for collection of ground water.
4
CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 61/110,175, filed Oct. 31, 2008, which is hereby incorporated by reference in its entirety for all purposes. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable. BACKGROUND 1. Field of the Invention This invention relates generally to the field of drilling. More specifically, the invention relates to compositions and methods for annular pressure buildup mitigation. 2. Background of the Invention Natural resources such as oil or gas residing in a subterranean formation are recovered by drilling a well into the formation. The subterranean formation is usually isolated from other formations using a technique known as well cementing. In particular, a wellbore is typically drilled down to the subterranean formation while circulating a drilling fluid through the wellbore. After the drilling is terminated, a string of pipe (e.g. drill string, casing) is run in the wellbore. Primary cementing is then usually performed where cement slurry is pumped down through the string of pipe and into the annulus between the string of pipe and the walls of the wellbore to allow the cement slurry to set into an impermeable cement column and thereby seal the annulus. Secondary cementing operations may also be performed after the primary cementing operation. After completion of the cementing operations, production of the oil or gas may commence. The oil and gas are produced at the surface after flowing through the wellbore. As the oil and gas pass through the wellbore, heat may be passed from such fluids through the casing and into the annular space, which typically results in expansion of any fluids in the annular space. Annular pressure build-up (APB) is a potentially dangerous condition in wells caused by a temperature driven increase in pressure within the annuli formed by downhole strings. APB situations commonly occur in subsea wells, where annuli between adjacent casing strings are sealed from above by wellhead equipment at the mudline and from below by cement tops or barite plugs. Pressure within the annuli is built up as the temperature within the annuli is increased due to the expansion of drilling fluids within the annuli. A significant increase in pressure within the annuli may have adverse consequences such as rupture of the casing wall or catastrophic collapse of the drilling string itself or of the production tubing through which wellbore fluids are brought to surface. Several techniques for mitigating APB have already been developed and employed with some regularity in the industry. One mitigator, for example, is syntactic foam composed of hollow glass elastic hollow particles with prescribed dimensions. The foam is attached to the outside surface of the inner string of the annulus. Onset of APB above a particular pressure level causes the elastic hollow particles to collapse and break, increasing the available volume of the annulus. These and other commonly used techniques, however, are limited in utility in that they provide only a one-time relief of APB; once activated, the mitigator cannot relieve future instances of pressure buildup. Consequently, there is a need for more effective compositions and methods for mitigating annular pressure buildup. BRIEF SUMMARY The concept involves placing within the annulus, hollow particles that possess material and geometric properties such that the hollow particles buckle at or near a defined pressure. Buckling of the particles increases the available volume within the annulus, thereby decreasing the annular pressure. The elastic hollow particles are designed such that they buckle in a sufficiently elastic manner to allow them to rebound towards their original shape as the pressure decreases. The rebounded particles then remain available to mitigate subsequent instances of APB. In an embodiment, a method of mitigating annular pressure buildup comprises providing a wellbore composition comprising a plurality of elastic hollow particles. The method further comprises introducing the wellbore composition to an annulus of a wellbore. In addition, the method comprises using the plurality of elastic hollow particles to mitigate annular pressure buildup. The elastic hollow particles buckle above an annular pressure threshold and rebound below the annular pressure threshold. In another embodiment, a method of mitigating annular pressure buildup comprises providing a wellbore composition comprising a plurality of elliptical hollow particle. The elliptical hollow particles are elastic. The method additionally comprises introducing the wellbore composition to an annulus of a wellbore. Moreover, the method comprises using the plurality of elliptical hollow particles to mitigate annular pressure buildup. The elliptical hollow particles buckle above an annular pressure threshold and rebound below the annular pressure threshold. In yet another embodiment, a method of mitigating annular pressure buildup comprises providing a wellbore composition comprising a plurality of elastic hollow particles having at least two segments. The method also comprises introducing the wellbore composition to an annulus of a wellbore. In addition, the method comprises using the plurality of elastic hollow particles to mitigate annular pressure buildup. The elastic hollow particles buckle above an annular pressure threshold and rebound below the annular pressure threshold. The foregoing has outlined rather broadly the features and technical advantages of the invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which: FIG. 1 illustrates an embodiment of an elastic hollow particle which may be used with the disclosed methods; FIG. 2 illustrates an elliptical embodiment of an elastic hollow particle which may be used with the disclosed methods; FIG. 3 illustrates a pressure-volume curve for the compression of water and a sample of polypropylene elastic hollow particles; FIG. 4 illustrates a pressure-volume curve for the compression of water and another sample of polypropylene elastic hollow particles; FIG. 5 illustrates a pressure-volume curve for the compression of water and another sample of polypropylene elastic hollow particles; FIG. 6 illustrates a pressure-volume curve for the compression of water and a sample of high-density polyethylene elastic hollow particles; and FIG. 7 illustrates a pressure-volume curve for the compression of water and another sample of high-density polyethylene elastic hollow particles. NOTATION AND NOMENCLATURE Certain terms are used throughout the following description and claims to refer to particular system components. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections. As used herein, the term “elastic” may refer to the ability of a material or particle to resume or return toward its original shape after compression or deformation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In general, embodiments of the disclosed methods for mitigating annular pressure buildup utilize a wellbore composition comprising a plurality of elastic hollow particles. FIG. 1 illustrates an embodiment of an elastic hollow particle 100 which may be used in the wellbore composition. In an embodiment, the elastic hollow particle 100 comprises a shell 103 of elastic polymeric material and an inner hollow cavity 105 . The plurality of elastic hollow particles 100 may be mixed with an existing wellbore fluid and injected into the annulus of a wellbore. In instances of annular pressure buildup, the elastic hollow particles 100 may buckle to alleviate the pressure within the annulus and effectively provide more volume within the annulus. Once the temperature within the annulus has been decreased and the APB as been reduced, elastic hollow particles 100 are capable of rebounding to their original shape and are, thus, re-usable for subsequent instances of APB. By comparison, existing particles and APB mitigators only provide for one time mitigation of APB. Elastic hollow particle 100 may be any suitable shape. In an embodiment, elastic hollow particle 100 may have a spherical shape. FIG. 1 shows an example of such an embodiment of elastic hollow particle with an outer spherical shape. In other embodiments, elastic hollow particle 100 may comprise variations of a sphere such as without limitation, prolate spheroid, oblate spheroid, spheres, ovoids (i.e. egg shaped), etc, such as depicted in FIG. 2 . In other words, elastic hollow particle 100 may comprise an elliptical hollow particle 100 a . Referring to FIG. 2D , elliptical hollow particle 100 a may have a semi-major axis, a, and a semi-minor axis, b. Axes a and b may be of any suitable length. More particularly, axis a may have a length ranging from about 50 mm to about 0.1 mm, alternatively from about 25 mm to about 2 mm, alternatively from about 5 mm to about 1 mm. Axis b may have a length ranging from about 50 mm to about 0.1 mm, alternatively from about 25 mm to about 2 mm, alternatively from about 5 mm to about 1 mm. In addition, axes a and b may be of any suitable ratio to each other. Referring to FIG. 2A , in an embodiment, elliptical hollow particle 100 a may have a circular cross-section (i.e. prolate spheroid). However, it is contemplated that elliptical hollow particle 100 a may also have an elliptical cross-section (i.e. oblate spheroid). As such, axes b and c in FIG. 2A may be different from one another and may be of any suitable ratio to one another. Axis c may be of any length. More particularly, axis c may have a length ranging from about 50 mm to about 0.1 mm, alternatively from about 25 mm to about 2 mm, alternatively from about 5 mm to about 1 mm. Inner cavity 105 if elastic hollow particle 100 may be filled with any suitable fluid or material (e.g. gas, liquid, foam) at a range of pressures (atmospheric or higher). Examples of suitable fluids include without limitation, air, inert gas, or combinations thereof. Inner cavity 105 of elastic hollow particle 100 may have the same geometry or a different geometry than that of the shell 103 . For example, shell 103 may comprise a spherical geometry while inner cavity may have a prolate spheriodal geometry. Furthermore, in some embodiments, elastic hollow particles 100 may comprise at least two segments 106 . That is, the elastic hollow particles 100 are segmented hollow particles. The elastic hollow particles 100 may be fabricated from any number of segments 106 . In one embodiment, elastic hollow particles have two segments 106 . The segments 106 may fit together via a snap-fit connection 109 or other suitable connection, such as for example, welding. Inner cavity 103 may be filled with any suitable fluid or material (e.g. gas, liquid, foam) at a range of pressures (atmospheric or higher). Examples of suitable fluids include without limitation, air, inert gas, or combinations thereof. Inner cavity 105 of elastic hollow particle 100 may have the same geometry or a different geometry than that of the shell 103 . For example, shell 103 may comprise a spherical geometry while inner cavity may have a prolate spheroidal geometry. Elastic hollow particles 100 may be manufactured by any methods known to those of skill in the art. In one embodiment, elastic hollow particles 100 may be made by injection molding. As mentioned above, shell 103 of elastic hollow particle 100 preferably comprises an elastic polymeric material. However, shell 103 may comprise any suitable material which exhibits the requisite elastic properties for mitigating annular pressure buildup. Examples of suitable polymeric materials include without limitation, polybutadiene, ethylene propylene diene (EPDM) rubber, silicone, polyurethane, polyamide, acetal, thermoplastic elastomers, polypropylene, polyethylene, polytetrafluoroethylene (PTFE), polyvinylidenefluoride (PVDF), or combinations thereof. The elastic polymeric material may be a copolymer, a random copolymer, a block copolymer, a multiblock copolymer, a polymer blend, or combinations thereof. The elastic hollow particles 100 may have any suitable diameter. More specifically, embodiments of the elastic hollow particles 100 may have an average outer diameter ranging from about 50 mm to about 0.1 mm, alternatively from about 25 mm to about 2 mm, alternatively from about 5 mm to about 1 mm. Additionally, elastic hollow particles 100 may have any suitable shell thicknesses. In particular, embodiments of the elastic hollow particles may have an average shell thickness ranging from about 10 mm to about 5 mm, alternatively from about 5mm to about 1 mm, alternatively from about 1 mm to about 0.1 mm. Inner cavity 105 of elastic hollow particle 100 may have any suitable diameter. For example, inner cavity 105 may have an average diameter ranging from about 50 mm to about 25 mm, alternatively from about 25 mm to about 5 mm, alternatively from about 5 mm to about 0.1 mm. In embodiments, the elastic hollow particles 100 have very specific mechanical properties in order to properly mitigate annular pressure buildup. In particular, elastic hollow particles 100 may have an elastic modulus at 25° C. ranging from about 100 GPa to about 10 MPa, alternatively from about 1 GPa to about 100 MPa, alternatively from about 100 MPa to about 10 MPa. Furthermore, elastic hollow particles 100 may have a yield strain at about 25° C. ranging from about 100% to about 50%, alternatively from about 50% to about 10%, alternatively from about 10% to about 1%. In other words, the elastic hollow particles 100 may be designed to buckle at a specific annular pressure and/or temperature. As used herein, “annular pressure threshold” is the pressure within the annulus for which the elastic hollow particles 100 may be designed to compress or buckle at a given temperature. Accordingly, the elastic hollow particles 100 may buckle or compress at an annular pressure threshold ranging from about 15,000 psi to about 10,000 psi, alternatively from about 10,000 psi to about 5,000 psi, alternatively from about 5,000 psi to about 500 psi. In addition, elastic hollow particles 100 provide greater volume compression than solid particles. Accordingly, each elastic hollow particle 100 may compress to an average volume ranging from about 99% to about 50% of its original volume, alternatively from about 50% to about 10% of its original volume, alternatively from about 10% to about 1% of its original volume. With respect to elasticity, the elastic hollow particles 100 preferably rebound or return to at least about 99% of their original volume, alternatively at least about 50% of their original volume, alternatively at least about 10% of their original volume. The elastic hollow particles 100 may be used in conjunction with any wellbore composition and/or fluids known to those of skill in the art. Examples of known wellbore fluids include without limitation, production fluids, drilling muds, spacer fluids, chemical pills, completion fluids, or combinations thereof. As such, the elastic hollow particles 100 may be present in a fluid composition at a concentration ranging from about 70 vol % to about 25 vol %, alternatively from about 25 vol % to about 1 vol %. The wellbore composition may include additional fluids and additives commonly used in existing wellbore treatment fluids. In particular, the wellbore composition may comprise an aqueous-based fluid or a nonaqueous-based fluid. Without limitation, examples of suitable aqueous-based fluids include fresh water, salt water (e.g., water containing one or more salts dissolved therein), brine (e.g., saturated salt water), seawater, water-based drilling fluids (e.g., water-based drilling fluid comprising additives such as clay additives), and combinations thereof. Examples of suitable nonaqueous-based fluids include without limitation, diesel, crude oil, kerosene, aromatic mineral oils, non-aromatic mineral oils, linear alpha olefins, poly alpha olefins, internal or isomerized olefins, linear alpha benzene, esters, ethers, linear paraffins, or combinations thereof. For instance, the non-aqueous-based fluids may be blends such as internal olefin and ester blends. In some embodiments, the additional fluids and/or additives may be present in the wellbore composition in an amount sufficient to form a pumpable wellbore fluid. The elastic hollow particles 100 may be placed in a subterranean annulus in any suitable fashion. For example, the elastic hollow particles 100 may be placed into the annulus directly from the surface. Alternatively, the elastic hollow particles 100 may be flowed into a wellbore as part of a wellbore composition via the casing and permitted to circulate into place in the annulus between the casing and the subterranean formation. Generally, an operator will circulate one or more additional fluids (e.g., a cement composition) into place within the subterranean annulus behind the well fluids of the present invention therein; in certain exemplary embodiments, the additional fluids do not mix with the well fluids of the present invention. At least a portion of the well fluids of the present invention then may become trapped within the subterranean annulus; in certain exemplary embodiments of the present invention, the well fluids of the present invention may become trapped at a point in time after a cement composition has been circulated into a desired position within the annulus to the operator's satisfaction. At least a portion of the elastic hollow particles 100 may collapse or reduce in volume so as to affect the pressure in the annulus. For example, if the temperature in the annulus should increase after the onset of hydrocarbon production from the subterranean formation, at least a portion of the hollow particles 100 may collapse or reduce in volume so as to desirably mitigate, or prevent, an undesirable buildup of pressure within the annulus. To further illustrate various illustrative embodiments of the present invention, the following examples are provided. EXAMPLE 1 A variety of industries and materials suppliers were surveyed to locate readily available, off-the-shelf hollow polymer particles. The search criteria were limited to the following: the particles had to be hollow and made of plastic or rubber, with an outside diameter of no more than 10 mm. While the downhole operating requirements are much more stringent, these relatively simple criteria allowed acquisition of particles that could serve as potential concept demonstrators. After considering a variety of experimental techniques for applying elevated pressures on the order of 15,000 psi and measuring changes in volume demonstrated by the elastic hollow particles, a High Pressure Pump Model 68-5.75-15 from High Pressure Equipment (HiP) was acquired. This device is a manual screw-driven pressure generator that is capable of applying pressures up to 15,000 psi in a small cylindrical chamber approximately 16 inches long and 11/16 inch in diameter. For each experiment, the test chamber was filled with a mixture of water and elastic hollow particles and care was taken to minimize the amount of air remaining in the chamber. A digital pressure gauge measured the pressure applied to the test samples, while a linear voltage displacement transducer (LVDT) on the drive screw measured the applied volume change. EXAMPLE 2 This experiment involved two pressure cycles up to 10,000 psi of an 11.6% mixture in volume of a sample of polypropylene hollow particles (Sample 1) and water. The elastic hollow particles used for this experiment had an outside diameter of 2.5 mm and a variable size cavity. Microscopic exploration revealed that the size of the cavity was minimal. As a result, the pressure-volume curve (as shown in FIG. 3 ) was very similar to that obtained in an experiment involving only the compression of water and residual air. EXAMPLE 3 This experiment involved two pressure cycles of a 5.6% mixture in volume of another sample of polypropylene elastic hollow particles (Sample 2) and water. Results are shown in FIG. 4 . The polypropylene elastic hollow particles had a 10 mm diameter and a 1 mm wall thickness. The sound of the elastic hollow particles collapsing could be heard under the increasing pressure. As seen in the pressure-volume response, every collapsed particle provided additional volume and relieved the pressure in the chamber. Most of the elastic hollow particles, with the exception of two, failed close to 2,000 psi. The failure mode representative of all ten elastic hollow particles is shown in FIG. 3 . The maximum pressure did not significantly exceed 2,000 psi until collapse of the final particle, which occurred at about 6.5% change in volume. This location on the plot is about 5% change in volume above the point at which the pressure first began to depart from 0 psi (1.5%). This value of 5% change in volume can be compared to the results of the experiment involving only water a residual air. In that experiment, the pressure exceeded 2,000 psi at about 4.5% change in volume, which is about 1.5% change in volume above the point at which the pressure first began to depart from 0 psi. These results show that collapse of the elastic hollow particles provided additional volume and prevented the pressure from increasing. Only when all elastic hollow particles were collapsed did the pressure increase dramatically. Selection of appropriate material and geometry for the elastic hollow particles could make this pressure relief available on a repeatable basis. EXAMPLE 4 The fourth experiment involved a single pressure cycle of a 3.4% volume fraction mixture of another sample of polypropylene elastic hollow particles (Sample 4) and water. The elastic hollow particles in this sample had a diameter of 10 mm and a wall thickness of 3 mm. The results are shown in FIG. 5 . As shown, the elastic hollow particles exhibited pressure relief at approximately 10,000 psi. The slope of the pressure-volume curve decreased in a gradual fashion as the elastic hollow particles collapsed. At the conclusion of the experiment, the chamber was opened and the elastic hollow particles were observed to be undeformed, indicating that the elastic hollow particles had collapsed elastically. Hysteresis in the first cycle indicated viscoelastic material behavior of the elastic hollow particles; deformation during the first cycle likely changed the material stiffness. In this respect, the first cycle likely “pre-conditioned” the hollow particles. It is expected that collapse during the second cycle would demonstrate behavior differing from that shown in the first cycle, yet would be repeatable in cycles beyond the second cycle. An issue with instrumentation caused this particular experiment to be terminated before the second cycle could be completed. Further experimentation with these hollow particles, particularly involving multiple pressure cycles, is necessary to confirm the above observations and to further understand the potential for pressure relief provided by these elastic particles. EXAMPLE 5 FIGS. 6 and 7 show the results of pressure-volume experiments performed with samples of elastic hollow particles fabricated with high-density polyethylene (HDPE). FIG. 6 shows results using HDPE elastic hollow particles with outer diameter of 0.25 inches and a shell thickness of 1.3 mm. FIG. 7 shows the results using HDPE elastic hollow particles with outer diameter of 10 mm and a shell thickness of 1 mm. These results provide further proof of concept that elastic hollow particles with different types of polymers may be applied to APB mitigation. While the embodiments of the invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of the invention. The embodiments described and the examples provided herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited by the description set out above, but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. The discussion of a reference is not an admission that it is prior art to the present invention, especially any reference that may have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated herein by reference in their entirety, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.
The concept involves placing within the annulus, hollow particles that possess material and geometric properties such that the hollow particles buckle at or near a defined pressure. Buckling of the particles increases the available volume within the annulus, thereby decreasing the annular pressure. The elastic hollow particles are designed such that they buckle in a sufficiently elastic manner to allow them to rebound towards their original shape as the pressure decreases. The rebounded particles then remain available to mitigate subsequent instances of APB.
4
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a receiving device and an integrated circuit for reception. [0003] 2. Description of the Related Art [0004] Digital audio radio services in the U.S. are called “DARS”, and in DARS, satellite waves and terrestrial waves are used in combination so that even a receiver mounted in a mobile unit such as vehicle can reliably receive the radio waves. [0005] More specifically, in the DARS, a 2.3 GHz band is used, and as shown in part B of FIG. 6 , two services are broadcast. Currently, each of the services uses a frequency band of 12.5 MHz. As is also shown in part A of FIG. 6 , one service is formed of two ensembles A and B, and each of these ensembles A and B provides 50 channels of programs contents. Therefore, one service provides programs of 100 channels. [0006] The ensemble A is broadcast with individual signals A 1 , A 2 , and A 3 , and the ensemble B is broadcast with individual signals B 1 , B 2 , and B 3 . That is, the contents of the signals A 1 , A 2 , and A 3 are the same, and the contents of the signals B 1 , B 2 , and B 3 are the same. Therefore, if any one of the signals A 1 , A 2 , and A 3 can be received, the program of the ensemble A can be listened to, and in a similar manner, if any one of the signals B 1 , B 2 , and B 3 can be received, the program of the ensemble B can be listened to. [0007] As is also shown in part A of FIG. 6 , the signals A 1 to A 3 and B 1 to B 3 are arranged as the signals A 1 , A 2 , A 3 , B 3 , B 2 , and B 1 in order of frequency, and the signals A 1 , A 2 , and A 3 , and the signals B 3 , B 2 , and B 1 are symmetrically placed about a center frequency fC between the signal A 3 and the signal B 3 . [0008] The signals A 1 , A 2 , B 1 , and B 2 are QPSK (Quadrature Phase Shift Keying) signals. The signals A 1 and B 1 are transmitted from a broadcasting satellite BS 1 over the Western U.S., and the signals A 2 and B 2 are transmitted from a broadcasting satellite BS 2 over the Eastern U.S. (strictly speaking, the satellites BS 1 and BS 2 are positioned along the Equator at longitudes corresponding to the Western U.S. and the Eastern U.S.). Also, the signals A 3 and B 3 are OFDM (Orthogonal Frequency Division Multiplex) signals and are transmitted from an antenna on the ground. [0009] Therefore, since the signals A 1 , A 2 , B 1 , and B 2 are satellite waves, and a diversity effect can be obtained by the satellites BS 1 and BS 2 , a broadcast can be listened to over the entire U.S. Also, when there is a high-rise building, radio waves are sometimes blocked, but this is compensated for by the signals A 3 and B 3 of the terrestrial waves. Therefore, even when the receiving conditions of radio waves of a receiver mounted in a vehicle greatly change as the vehicle travels, it is possible to satisfactorily receive a broadcast. [0010] In DARS, since the signals A 1 to A 3 and B 1 to B 3 are broadcast by frequency division in the above-described manner, a receiver therefor is constructed as shown in, for example, FIG. 7 . In the following description, for brevity of explanation, as shown in FIG. 8A , the signals A 1 and A 2 are collectively denoted as A 12 , and the signals B 1 and B 2 are collectively denoted as B 12 . [0011] More specifically, in FIG. 7 , the signals A 12 , A 3 , B 12 , and B 3 are received by an antenna 11 , and the received signals A 12 to B 3 are supplied to a first mixer circuit 14 via a band-pass filter 12 and a high-frequency amplifier 13 . Furthermore, a first local oscillation signal SLO is supplied from a first local oscillation circuit 15 to the first mixer circuit 14 , whereby the signals A 12 to B 3 are frequency-converted into first intermediate frequency signals. [0012] When the ensemble A is to be listened to (when the signals A 1 to A 3 are subjects to be received), as indicated by the solid line in FIG. 8A , the first local oscillation signal SLO is set to a predetermined frequency fL which is lower than those of the signals A 12 and A 3 . Therefore, as shown in FIG. 8B , the signal A 12 is frequency-converted into a first intermediate frequency signal SIF 12 (at intermediate frequency fIF 12 ), the signal A 3 is frequency-converted into a first intermediate frequency signal SIF 3 (at intermediate frequency fIF 3 ), and the signals B 12 and B 3 are frequency-converted into first intermediate frequency signals SIF 45 and SIF 6 , respectively. [0013] When the image rejection characteristics are taken into consideration, the first intermediate frequencies fIF 12 and fIF 3 cannot be decreased too much, and since a frequency band of 2.3 GHz is used in a broadcast, the first intermediate frequencies fIF 12 and fIF 3 are set to 100 MHz or higher. For example, the following are set: fIF 12 is approximately 113 MHz, and fIF 3 is approximately 116 MHz [0015] Also, when the ensemble B is to be listened to (when the signals B 1 to B 3 are subjects to be received), as indicated by the broken line in FIG. 8A , the first local oscillation signal SLO is set to a predetermined frequency fH which is higher than those of the signals B 12 and B 3 . Therefore, as shown in FIG. 8C , the signal B 12 is frequency-converted into a first intermediate frequency signal SIF 12 (at intermediate frequency fIF 12 ), the signal B 3 is frequency-converted into a first intermediate frequency signal SIF 3 (at intermediate frequency fIF 3 ), and the signals A 12 and A 3 are frequency-converted into first intermediate frequency signals SIF 45 and SIF 6 , respectively. [0016] Therefore, when any one of the ensembles A and B is to be listened to, the intermediate frequency signals SIF 12 to SIF 6 are supplied to a band-pass filter 21 L for a first intermediate-frequency filter, whereby an intermediate frequency signal SIF 12 is extracted. Then, this signal is supplied to a second mixer circuit 22 L, a second local oscillation signal having a predetermined frequency is provided from a second local oscillation circuit 23 , and this signal is supplied to the mixer circuit 22 L, whereby the signal SIF 12 is frequency-converted into a second intermediate frequency signal. Then, this signal is supplied to a demodulation circuit 25 L via a variable gain amplifier 24 L for AGC (Automatic Gain Control), whereby a digital audio signal of the target program is demodulated, and this signal is supplied to a selecting/combining circuit 26 . [0017] Also, the signals SIF 12 to SIF 6 from the first mixer circuit 14 is supplied to a band-pass filter 21 H for a first intermediate frequency filter, whereby the intermediate frequency signal SIF 3 is extracted. Then, this signal is supplied to a second mixer circuit 22 H, and furthermore, a second local oscillation signal from the second local oscillation circuit 23 is supplied to the mixer circuit 22 H, whereby the signal SIF 3 is frequency-converted into a second intermediate frequency signal. Then, this signal is supplied to a demodulation circuit 25 H via a variable gain amplifier 24 H for AGC, whereby a digital audio signal of the target program is demodulated, and this signal is supplied to the selecting/combining circuit 26 . [0018] Then, in the selecting/combining circuit 26 , the signal from the demodulation circuit 25 L and the signal from the demodulation circuit 25 H are selected or combined, and is output at an output terminal 27 . [0019] Therefore, as a result of switching the frequency of the first local oscillation signal SLO to a frequency fL or a frequency fH, a digital signal of the ensemble A or a digital signal of the ensemble B is output at the terminal 27 . [0020] Then, at that time, when the ensemble A is received, since the digital signal demodulated from the received signal A 12 and the digital signal demodulated from the received signal A 3 are selected or combined, and is taken out at the terminal 27 , a digital signal having a small amount of error can be obtained regardless of the receiving conditions. Furthermore, also when the ensemble B is received, a digital signal having a small amount of error can be obtained regardless of the receiving conditions for the same reasons. [0021] However, in the above-described receiver, when the ensemble is switched from the ensemble A to the ensemble B, it is necessary to change the frequency of the first local oscillation signal SLO from the frequency fL to the frequency fH. That is, as is also clear from FIGS. 8A to 8 C, it is necessary to change the frequency of the first local oscillation signal SLO to a frequency larger than the occupied bandwidth 12.5 MHz of the services of the signals A 1 to A 3 and B 1 to B 3 . Also, the same applies to a case in which the ensemble is changed from the ensemble B to the ensemble A. [0022] The amount of change of this frequency is equal to or more than 10% of the frequencies fL and fH. Moreover, when the first local oscillation circuit 15 is formed by a PLL (Phase-Locked Loop), it is necessary to allow for some margin with respect to the range of change of the oscillation frequency of the VCO (Voltage Controlled Oscillator) of the PLL. For this reason, it is necessary to increase the range of change of the oscillation frequency of the VCO by making the resonance device of the VCO changeable. As a result, the construction becomes complex, and the phase noise characteristics of the local oscillation signal SLO deteriorate, causing the error rate of the digital signal to become worse. [0023] Also, as long as the first local oscillation circuit 15 is formed by a PLL, it takes time to change the frequency, and the ensemble cannot be received during that change. [0024] In addition, the first intermediate frequencies fIF 12 and fIF 3 are increased to 100 MHz or higher in the above-described manner, and as shown in FIGS. 8B and 8C , it is necessary for the filters 21 L and 21 H to extract the first intermediate frequency signals SIF 12 and SIF 3 from within the crowded signals. As a result, the filters 21 L and 21 H are formed by an SAW (Surface Acoustic Wave) filter. For this reason, the cost increases, and when the circuit is formed into an IC (integrated circuit), the SAW filter must be provided externally. Furthermore, this becomes an obstacle to the reduction in size of the receiver. [0025] Also, when the demodulation of the demodulation circuits 25 L and 25 H is to be performed by a digital process, an intermediate frequency signal supplied to the demodulation circuits 25 L and 25 H must be formed into a frequency at which a digital process is possible. For this purpose, as is also shown in FIG. 7 , for the receiving method, a double conversion method must be used, the construction becomes complex, and the number of parts is increased. SUMMARY OF THE INVENTION [0026] The present invention aims to solve such problems as those described above. [0027] Accordingly, an object of the present invention is to provide a receiving device comprising: a receiving circuit for receiving a first signal and a second signal which are transmitted at mutually different frequencies; a circuit for forming-first and second local oscillation signals, whose frequencies are both the center frequency between the first signal and the second signal, and whose phases differ by 90° from each other; a first mixer circuit for frequency-converting the received signal received by the receiving circuit into a first intermediate frequency signal in accordance with the first local oscillation signal; a second mixer circuit for frequency-converting the received signal received by the receiving circuit into a second intermediate frequency signal in accordance with the second local oscillation signal; a first phase-shift circuit to which the first intermediate frequency signal is supplied; a second phase-shift circuit to which the second intermediate frequency signal is supplied, in which the amount of the phase shift differs by 90° from that of the first phase-shift circuit; and an addition/subtraction circuit for performing one of addition and subtraction between the output signal of the first phase-shift circuit and the output signal of the second phase-shift circuit, wherein, by switching the process in the addition/subtraction circuit to the addition or the subtraction, the intermediate frequency signal corresponding to the first signal or the intermediate frequency signal corresponding to the second signal is selectively extracted from the addition/subtraction circuit. [0028] Therefore, while the local oscillation frequency is being fixed, the first signal or the second signal is selected. [0029] In particular, a receiving device is provided which is suitable for a case in which each of the first and second signals is formed of a signal of a plurality of programs, and the signals of individual programs are transmission programs which are arranged according to frequency symmetrically with respect to the center frequency. [0030] More specifically, when the ensemble is to be switched, since the frequency of the local oscillation signal does not need to be changed, the local oscillation circuit does not become complex. Also, the deterioration of the phase noise characteristics of the local oscillation signal, and the deterioration of the error rate of the digital signal do not occur. Furthermore, when the ensemble is to be switched, the switching can be performed easily at high speed, and the problem where the ensemble cannot be received during the switching, like when the local oscillation frequency is to be changed, does not occur. [0031] Another object of the present invention is to provide a reception integrated circuit which is suitable for constructing the above-described receiving device. According to the integrated circuit of the present invention, in addition to the above-described features, the intermediate-frequency filter can be formed by an active filter, and can be integrally formed into a one-chip IC with other circuits. This is effective in reducing the cost and the size of the receiver. Furthermore, even when demodulation is to be performed by a digital process, a single conversion may be used for the receiving method, the construction becomes simple, and the number of parts is decreased. [0032] The above and further objects, aspects and novel features of the invention will become more fully apparent from the following detailed description when read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0033] FIG. 1 is a block diagram showing an embodiment of the present invention; [0034] FIGS. 2A, 2B , and 2 C are frequency spectrum diagrams illustrating the present invention; [0035] FIG. 3 is a block diagram showing another embodiment of the present invention; [0036] FIG. 4 is a circuit diagram showing a part of the other embodiment of the present invention; [0037] FIG. 5 is a circuit diagram showing a part of the other embodiment of the present invention; [0038] FIG. 6 is a frequency spectrum diagram illustrating DARS; [0039] FIG. 7 is a block-diagram showing the present invention; and [0040] FIGS. 8A, 8B , and 8 C are frequency spectrum diagrams illustrating the circuit of FIG. 7 . DESCRIPTION OF THE PREFERRED EMBODIMENTS [0041] FIG. 1 shows an example of a DARS receiving circuit according to the present invention, in which a portion 30 surrounded by a one-dot chain line is formed into a one-chip IC. Signals A 1 to A 3 , and B 1 to B 3 are received by an antenna 51 , and the received signals A 1 to B 3 are supplied to mixer circuits 32 I and 32 Q via a band-pass filter 52 , which is formed of, for example, an SAW filter and which has a passing bandwidth of 12.5 MHz and furthermore via a high-frequency amplifier 31 . [0042] In a local oscillation circuit 33 , as shown in FIG. 2A , an oscillation signal SLO having a frequency equal to the center frequency fC between the signal A 3 and the signal B 3 is formed, this signal SLO is supplied to a phase processing circuit 34 , whereby two local oscillation signals SLI and SLQ, whose phases differ by 90° from each other, with the frequency being kept at the value fC, are formed, and these signals SLI and SLQ are supplied to the mixer circuits 32 I and 32 Q, respectively. [0043] In the following description, for brevity of explanation, it is assumed that, as shown in FIG. 2A , the signal SA represents each of the signals A 1 to A 3 , and the signal SB represents each of the signals B 1 to B 3 . That is, it is assumed that SA=A 1 , SA=A 2 , or SA=A 3 , and that SB =B 1 , SB=B 2 , or SB=B 3 . Then, it is arranged that: SA=EA· sin ω At SB=EB· sin ω Bt where EA is the amplitude of the signal SA, EB is the amplitude of the signal SB, ωA is the angular frequency of the signal SA, and ωB is the angular frequency of the signal SB. Also, it is arranged that: SLI=EL· sin ω Ct SLQ=EL ·cos ω Ct where EL is the amplitude of the signals SLI and SLQ, and ωC=2πfC. [0044] Then, from the mixer circuits 32 I and 32 Q, signals SIFI and SIFQ as described below are extracted: SIFI = ( SA + SB ) × SLI   ⁢ = EA · sin ⁢   ⁢ ω ⁢   ⁢ At × EL · sin ⁢   ⁢ ω ⁢   ⁢ Ct + EB · sin ⁢   ⁢ ω ⁢   ⁢ Bt × EL · sin ⁢   ⁢ ω ⁢   ⁢ Ct   ⁢ = α ⁢ { cos ⁢   ⁢ ( ω ⁢   ⁢ A - ω ⁢   ⁢ C ) ⁢ t - cos ⁢   ⁢ ( ω ⁢   ⁢ A + ω ⁢   ⁢ C ) ⁢   ⁢ t } +   ⁢ β ⁢ { cos ⁡ ( ω ⁢   ⁢ B - ω ⁢   ⁢ C ) ⁢ t - cos ⁡ ( ω ⁢   ⁢ B + ω ⁢   ⁢ C ) ⁢ t } SIFQ = ( SA + SB ) × SLQ   ⁢ = EA · sin ⁢   ⁢ ω ⁢   ⁢ At × EL · cos ⁢   ⁢ ω ⁢   ⁢ Ct + EB · sin ⁢   ⁢ ω ⁢   ⁢ Bt × EL · cos ⁢   ⁢ ω ⁢   ⁢ Ct   ⁢ = α ⁢ { sin ⁡ ( ω ⁢   ⁢ A + ω ⁢   ⁢ C ) ⁢ t + sin ⁡ ( ω ⁢   ⁢ A - ω ⁢   ⁢ C ) ⁢ t } +   ⁢ β ⁢ { sin ⁡ ( ω ⁢   ⁢ B + ω ⁢   ⁢ C ) ⁢ t + sin ⁡ ( ω ⁢   ⁢ B - ω ⁢   ⁢ C ) ⁢ t } where α=EA·EL/2, and β=EB·EL/2 [0045] As will be described later, of the signals SIFI and SIFQ, the signal components of angular frequencies (ωA−ωC) and (ωB−ωC) are used as the intermediate frequency signals, and the signal components of angular frequencies (ωA+ωC) and (ωB+ωC) are removed by the intermediate frequency filter. Therefore, for the sake of simplicity, if the signal components of angular frequencies (ωA+ωC) and (ωB+ωC) to be removed are ignored, the above equations become: SIFI= α·cos(ω A−ωC ) t+β· cos(ω B−ωC ) t SIFQ=α ·sin(ω A−ωC ) t+β ·sin(ω B−ωC ) t [0046] Here, if it is arranged that ωA=ωC−Δω with regard to the signal SA, since, as is also shown in FIG. 2A , the signal SA and the signal SB are symmetrically distributed about the frequency fC, the following equation holds: ωB=ωC+Δω [0047] Then, if these equations are substituted in the equations for the signals SIFI and SIFQ, the following equations are obtained: SIFI = α · cos ⁡ ( ω ⁢   ⁢ C - Δ ⁢   ⁢ ω - ω ⁢   ⁢ C ) ⁢ t + β · cos ⁡ ( ω ⁢   ⁢ C + Δ ⁢   ⁢ ω - ω ⁢   ⁢ C ) ⁢ t   ⁢ = α · cos ⁡ ( - Δ ⁢   ⁢ ω ) ⁢ t + β · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t   ⁢ = α · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t + β · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t SIFQ = α · sin ⁡ ( ω ⁢   ⁢ C - Δ ⁢   ⁢ ω - ω ⁢   ⁢ C ) ⁢ t + β · sin ⁡ ( ω ⁢   ⁢ C + Δ ⁢   ⁢ ω - ω ⁢   ⁢ C ) ⁢ t   ⁢ = α · sin ⁡ ( - Δ ⁢   ⁢ ω ) ⁢ t + β · sin ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t   ⁢ = - α · sin ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t + β · sin ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t [0048] These signals SIFI and SIFQ are then supplied to phase-shift circuits 35 I and 35 Q. The phase-shift circuits 35 I and 35 Q are formed by an active filter in which, for example, a capacitor, a resistor, and an operational amplifier are used. The phase-shift circuit 35 I phase-shifts the signal SIFI by a value φ (φ is an arbitrary value), and the phase-shift circuit 35 Q phase-shifts the signal SIFQ by a value (φ+90°). [0049] In this manner, the phase-shift circuits 35 I and 35 Q cause the signal SIFQ to lead the signal SIFI by 90°, and the following equations hold: SIFI = α · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t + β · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t SIFQ = - α · sin ⁡ ( Δ ⁢   ⁢ ω ⁢   ⁢ t + 90 ⁢ ° ) + β · sin ⁡ ( Δ ⁢   ⁢ ω ⁢   ⁢ t + 90 ⁢ ° )   ⁢ = - α · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t + β · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t Therefore, between the signal SIFI and the signal SIFQ, the signal components α·cos Δωt are at the opposite phase from each other, and the signal components β·cos Δωt are in phase. [0050] These signals SIFI and SIFQ are then supplied to an addition/subtraction circuit 36 , and a control signal SSW is supplied from a terminal 37 to the addition/subtraction circuit 36 . This control signal SSW controls the operation of the addition/subtraction circuit 36 in such a way that when the program of the ensemble A is to be listened to, the addition/subtraction circuit 36 acts as a subtraction circuit, and when the program of the ensemble B is to be listened to, the addition/subtraction circuit 36 acts as an addition circuit. [0051] Therefore, a signal SIF such as that described below is extracted from the addition/subtraction circuit 36 in such a manner as to correspond to the control signal SSW. That is, during subtraction, the following is extracted: SIF = SIFI - SIFQ = 2 ⁢   ⁢ α · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t = EL · EA · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t , and during addition, the following is extracted: SIF = SIFI + SIFQ = 2 ⁢   ⁢ β · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t = EL · EB · cos ⁢   ⁢ Δ ⁢   ⁢ ω ⁢   ⁢ t [0052] Here, the signal SIF=EL·EA·cos Δωt which is obtained during subtraction is, as is also shown in FIG. 2B , the same intermediate frequency signal when the signal SA is received. The signals SIF 1 to SIF 3 contained in this signal SIF are the intermediate frequency signals of the signals A 1 to A 3 . Also, the signal SIF=EL·EB·cos Δωt which is obtained during addition is, as is also shown in FIG. 2C , the same intermediate frequency signal when the signal SB is received. The signals SIF 1 to SIF 3 contained in this signal SIF are the intermediate frequency signals of the signals B 1 to B 3 . [0053] Therefore, this signal SIF is supplied to a band-pass filter 41 H for an intermediate-frequency filter having passing characteristics such as those indicated by the broken line in, for example, FIGS. 2B and 2C , whereby an intermediate frequency signal SIF 3 of a terrestrial-wave signal A 3 or B 3 is extracted. At this time, the intermediate frequency signals SIF 1 and SIF 2 and the above-mentioned signal components of angular frequencies (ωA+ωC) and (ωB+ωC) are removed by the band-pass filter 41 H. [0054] Then, this intermediate frequency signal SIF 3 is supplied to a demodulation circuit 43 H via a variable gain amplifier 42 H for AGC, whereby a digital audio signal of the target program is demodulated, and this signal is supplied to a selecting/combining circuit 44 . [0055] Also, the signal SIF from the addition/subtraction circuit 36 is supplied to a band-pass filter 41 L for an intermediate-frequency filter having passing characteristics such as those indicated by the broken line in, for example, FIGS. 2B and 2C , whereby intermediate frequency signals SIF 2 and SIF 1 of the satellite-wave signals A 1 and A 2 , or B 1 and B 2 are extracted. At this time, the intermediate frequency signal SIF 3 and the above-mentioned signal components of angular frequencies (ωA+ωC) and (ωB+ωC) are removed by the filter 41 L. [0056] Then, these intermediate frequency signals SIF 2 and SIF 1 are supplied to a demodulation circuit 43 L via a variable gain amplifier 42 L for AGC, whereby a digital audio signal of the target program is demodulated, and this signal is supplied to the selecting/combining circuit 44 . [0057] Then, in the selecting/combining circuit 44 , the digital signal from the demodulation circuit 43 H and the digital signal from the demodulation circuit 43 L are selected or combined according to the received status of the signals A 1 to B 3 , and is extracted at an output terminal 45 . Of course, when it is desired to give priority to a receiving environment of a mobile unit in which the receiver is mounted and to satellite-wave reception, the AGC voltage obtained from the level detection circuit 46 L may be supplied as a gain control signal. [0058] At this time, parts of the intermediate frequency signals from the demodulation circuits 43 H and 43 L are supplied to level detection circuits 46 H and 46 L, whereby AGC voltages are formed, and these AGC voltages are supplied, as gain control signals, to the amplifiers 42 H and 42 L, whereby AGC is performed. [0059] In addition, although the level variation of the satellite wave is relatively small, the level variation of the terrestrial wave is relatively large. Therefore, for the high-frequency amplifier 31 , a variable gain amplifier is used, and the AGC voltage obtained from the level detection circuit 46 H is supplied, as a gain control signal, to the amplifier 31 , whereby AGC is performed. [0060] In this manner, according to the receiving circuit of FIG. 1 , a broadcast by DARS can be received, and in a case where the ensemble is switched between the ensemble A and the ensemble B, the frequency fC of the local oscillation signals SLI and SLQ does not need to be changed. Consequently, the local oscillation circuit 33 may be formed in a standard construction and does not become complex. Also, since the phase noise characteristics of the local oscillation signals SLI and SLQ are not decreased, the error rate of the digital signal does not become worse. [0061] In addition, when the ensemble is to be switched, the addition/subtraction circuit 36 need only be switched to an addition operation or a subtraction operation. Consequently, the switching can be performed at high speed, and the problem of not being able to receive the ensemble during switching time does not occur. [0062] As is also clear from FIGS. 2B and 2C , since the upper-limit frequency of the occupied bandwidth of the intermediate frequency signal SIF is equal to a half of the bandwidth of one ensemble, and the center frequencies of the filters 41 H and 41 L become approximately 1.3 MHz and 4.4 MHz, it is possible to form each of the filters 41 H and 41 L by an active filter. Therefore, it is possible to form the entirety into a one-chip IC as an IC 30 , excluding a band-pass filter 52 at the antenna input stage, and this is effective in reducing the costs and the size of the receiver. [0063] In addition, since the intermediate frequency of the intermediate frequency signals SIF 3 to SIF 1 is as low as several MHz, even when the demodulation of the demodulation circuits 43 H and 43 L is performed by a digital process, as shown in, for example, FIG. 1 , for the receiving method, a single conversion may be used, the construction becomes simple, and the number of parts is decreased. [0064] In the receiving circuit shown in FIG. 3 , a case is shown in which, by inverting or non-inverting the phase of the local oscillation signal SLQ when the ensemble A is received and when the ensemble B is received, the signals SIFI and SIFQ are always added together. [0065] More specifically, in the receiving circuit in FIG. 3 , the control signal SSW is supplied as a phase control signal to the phase processing circuit 34 , so that the phase of the local oscillation signal SLQ is controlled such that: SLQ=+EL·cos ωCt . . . when the ensemble B is received, and SLQ=−EL·cos ωCt . . . when the ensemble A is received. The phase of the local oscillation signal SLI is fixed, as described above: SLI=EL· sin ω Ct [0068] In place of the addition/subtraction circuit 36 in FIG. 1 , an addition circuit 38 is provided, and the signals SIFI and SIFQ output from the phase-shift circuits 35 I and 35 Q are supplied to the addition circuit 38 . [0069] According to such a construction, in the case of SLQ=+EL·cos ωCt, in the addition circuit 38 , the signal SIFI and the signal SIFQ are added together. Therefore, as is described with reference to the receiving circuit of FIG. 1 , the signal SIF extracted from the addition circuit 38 becomes as follows: SIF=SIFI+SIFQ=EL·EB· cos Δω t Therefore, it is possible to listen to the program of the ensemble B. [0070] On the other hand, in the case of SLQ=−EL·cos ωCt, the output signal of the phase-shift circuit 35 Q becomes the signal −SIFQ. Therefore, since, in the addition circuit 38 , subtraction between the signal SIFI and the signal SIFQ is performed, as is described with reference to the receiving circuit of FIG. 1 , the signal SIF extracted from the addition circuit 38 becomes: SIF=SIFI−SIFQ=EL·EA·cos Δωt Therefore, it is possible to listen to the program of the ensemble A. [0071] In this way, also in the receiving circuit of FIG. 3 , a DARS broadcast can be received. In particular, according to the receiving circuit of FIG. 3 , in a case where the ensemble is switched between the ensemble A and the ensemble B, it is only necessary to invert or non-invert the phase of the local oscillation signal SLQ by the phase processing circuit 34 . Therefore, the ensemble can be switched quickly. Also, since the phase-shift circuits 35 I and 35 Q and the addition circuit 38 can be formed by a poly-phase filter, the phase characteristics of the signal SIFI and the signal SIFQ can be improved. [0072] In FIG. 4 , a case is shown in which the phase of the intermediate frequency signal SIFI is constant regardless of the ensemble which is received, but the phase of the intermediate frequency signal SIFQ is inverted or non-inverted between when the ensemble A is to be received and when the ensemble B is to be received. [0073] More specifically, the mixer circuit 32 Q is formed as a double balanced-type by transistors Q 321 to Q 327 . The received signals A 1 to A 3 and B 1 to B 3 are extracted as a balanced type from the amplifier 31 and are supplied to transistors Q 322 and Q 323 . Furthermore, the local oscillation signal SLQ is extracted as a balanced type from the phase processing circuit 34 and is supplied to transistors Q 324 , Q 327 , Q 325 , and Q 326 . [0074] Consequently, the intermediate frequency signal SIFQ is extracted as a balanced type from the mixer circuit 32 Q. That is, for example, the intermediate frequency signal +SIFQ is extracted from the transistors Q 324 and Q 326 , and the intermediate frequency signal −SIFQ is extracted from the transistors Q 325 and Q 327 . [0075] Then, these intermediate frequency signal ±SIFQ are supplied to a switching circuit 39 . This switching circuit 39 is formed as a balanced type by transistors Q 391 to Q 397 , and the intermediate frequency signals ±SIFQ which are supplied thereto are supplied to a phase-shift circuit 36 Q in accordance with the control signal SSW with the phase kept as it is or with the phase being inverted. [0076] More specifically, based on the control signal SSW, when the transistor Q 395 is on and transistor Q 396 is off, the transistors Q 392 and Q 393 are turned on, and the transistors Q 391 and Q 394 are turned off. Therefore, the intermediate frequency signal +SIFQ extracted from the transistors Q 324 and Q 326 is supplied to one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 392 . Also, the intermediate frequency signal −SIFQ extracted from the transistors Q 325 and Q 327 is supplied to the other one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 393 . [0077] However, based on the control signal SSW, when the transistor Q 396 is on and the transistor Q 395 is off, the transistors Q 391 and Q 394 are turned on, and the transistors Q 392 and Q 393 are turned off. Therefore, the intermediate frequency signal +SIFQ extracted from the transistors Q 324 and Q 326 is supplied to the other one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 391 . Also, the intermediate frequency signal −SIFQ extracted from the transistors Q 325 and Q 327 is supplied to one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 394 . [0078] Therefore, since the phase of the intermediate frequency signal SIFQ supplied to the phase-shift circuit 36 Q is inverted or non-inverted in accordance with the control signal SSW, the intermediate frequency signal SIF of the ensemble A or the ensemble B is output from the addition circuit 38 . In this case, since the phase of the intermediate frequency signal SIFQ need only be inverted or non-inverted by the switching circuit 39 , it is possible to quickly switch the ensemble. [0079] Although the phase of the intermediate frequency signal SIFI is kept fixed, the intermediate frequency signal SIFI output from the mixer circuit 32 I may be supplied to a phase-shift circuit 36 I via a switching circuit having the same construction as that of the switching circuit 39 , and the switching circuit may be kept fixed. [0080] FIG. 5 shows a circuit 34 Q of a portion which switches the phase of the local oscillation signal SLQ within the phase processing circuit 34 in FIG. 3 . That is, the mixer circuit 32 Q is formed as a double balance-type as described in FIG. 4 , and the received signals A 1 to A 3 and B 1 to B 3 are extracted as a balanced type and are supplied to the transistors Q 322 and Q 323 . [0081] Furthermore, the switching circuit 34 Q is formed as a double balanced-type by the transistors Q 341 to Q 347 . The local oscillation signal +SLQ of one of the phases is supplied to the transistors Q 345 and Q 346 , and the local oscillation signal −SLQ of the other phases is supplied to the transistors Q 344 and Q 347 . Also, the balanced-type control signal SSW is supplied to the transistors Q 342 and Q 343 . [0082] Then, based on the control signal SSW, when the transistor Q 342 is on and the transistor Q 343 is off, the transistors Q 344 and Q 345 are turned on, and the transistors Q 346 and Q 347 are turned off. Therefore, the local oscillation signal +SLQ is supplied to the transistors Q 324 to Q 327 via the transistor Q 345 and further via the emitter-follower transistor Q 349 . Also, the local oscillation signal −SLQ is supplied to the transistors Q 325 and Q 326 via the transistor Q 344 and further via the emitter-follower transistor Q 348 . [0083] However, based on the control signal SSW, when the transistor Q 343 is on and the transistor Q 342 is off, the transistors Q 346 and Q 347 are turned on, and the transistors Q 344 and Q 345 are turned off. Therefore, the local oscillation signal +SLQ is supplied to the transistors Q 325 and Q 326 via the transistor Q 346 and further via the transistor Q 348 . Also, the local oscillation signal −SLQ is supplied to the transistors Q 324 and Q 327 via the transistor Q 347 and further via the transistor Q 349 . [0084] Therefore, since the phase of the local oscillation signal SLQ supplied to the mixer circuit 32 Q is made to lead or reversed in accordance with the control signal SSW, the intermediate frequency signal SIF of the ensemble A or the ensemble B is output from the addition circuit 38 . Also in this case, since the phase of the local oscillation signal SLQ need only be inverted or non-inverted by the switching circuit 34 Q, the ensemble can be switched quickly. [0085] Many different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in this specification. To the contrary, the present invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention as hereafter claimed. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications, equivalent structures and functions.
In order to improve various characteristics of a receiving circuit for digital radio services, circuits are provided for forming two local oscillation signals, whose frequencies are both the center frequency between a first ensemble and a second ensemble, and whose phases differ by 90° from each other. Furthermore, there are provided mixer circuits for frequency-converting the received signal into intermediate frequency signals in accordance with the local oscillation signals, phase-shift circuits to which the intermediate frequency signals are supplied, and an addition/subtraction circuit for performing one of addition and subtraction of the outputs of the phase-shift circuits. In addition, there are provided intermediate frequency filters to which the output signal of the addition/subtraction circuit is supplied and demodulation circuits to which the output signals of the intermediate frequency filters are supplied. By switching the process in the addition/subtraction circuit to addition or subtraction, the signals of the first ensemble and the second ensemble are selectively extracted from the demodulation circuits.
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