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FIELD OF THE INVENTION
[0001] The invention relates to a yarn feeding device and more specifically to the use of an electric synchronous motor for controlling a yarn feeding device.
BACKGROUND OF THE INVENTION
[0002] The yarn feeding device known from EP 0 580 267 A1 comprises a pre-control device using the signals of a position sensor provided in the yarn feeding device in order to slowly drive the electric motor after switching off the electric motor by the speed control device until the winding element reaches a predetermined rotational position in relation to the housing. The control effort needed is considerable.
[0003] The yarn feeding device as known from EP 0 327 973 A (U.S. Pat. No. 4,936,356) is provided with a detector fixed to the housing which detector can be actuated by a transmitter rotating with the winding element in order to adjust the winding element with slow rotational speed into a predetermined position relative to the housing when the speed control device has to switch off the electric motor. The predetermined position of the winding element e.g. may be appropriate in order to facilitate threading of the yarn through the yarn feeding device.
[0004] U.S. Pat. No. 4,814,677 A generally discloses a field orientation control system of a permanent magnet motor operating by sinusoidal stator part actuation. The information on the momentary rotary position of the rotor is derived from measured stator voltages and stator currents. This is carried out without additional position sensors. The detected relative rotary positions of the rotor are used for the speed control and the torque control of the permanent magnet motor.
[0005] The so-called brushless DC motor (BLDC) known from EP 10 52 766 A2 (U.S. Pat. No. 6,356,048) is employed as the drive source for the winding element of a yarn feeding device. The motor is designed without sensors. A control system is provided for controlling the torque and/or the speed of the motor. The control system calculates the commutation switching points for the stator parts in six angled positions which are distant by a respective 60° without a position sensor. In this case the zero crossing points of the backwards acting electromotoric force are determined which are induced in the stator windings by the rotation of the rotor magnets. In-between the six switching points, distributed about a full revolution, the position of the rotor remains unknown. The backwards acting electromotoric force is effected according to a trapezoidal course. This motor drive control principle does not allow a sufficiently accurate position control and position observation of the winding element because only predetermined rotary positions of the rotor are detected.
SUMMARY OF THE INVENTION
[0006] It is an object of the invention to provide a yarn feeding device of the kind as disclosed herein which allows in a structurally simple and controllable fashion an accurate position control and/or position observation of the winding element in order to selectively and precisely reproducibly adjust a predetermined rotary position of the winding element which rotary position is needed for an auxiliary function of the yarn feeding device.
[0007] Additionally, this object can be achieved particularly expediently and simply by employing an electric synchronous motor for the control of the yarn feeding device, particularly a permanent magnet motor, which operates with permanent (continuous) stator vector control and sinusoidal stator actuation, in order to carry out the position control and/or position observation of the winding element in relation to the housing of the yarn feeding device, and to use for that purpose the information about the respective rotary position of the rotor which anyhow is needed for the permanent (continuous) stator vector control.
[0008] The speed device equipped with the microprocessor detects permanently (continuously) the relative rotary position of the vector of the rotor which position corresponds to the momentary rotary position of the rotor. This is carried out to permanently (continuously) rotate the stator vector generated by the sinusoidal actuation of the stator part such that the desired speed and/or the desired torque is gained substantially steplessly. The information on the momentary rotary position of the rotor or the rotor vector, respectively, is used to adjust the winding element into the at least one predetermined relative position in the housing by using the fixed structural correlation between the rotor, the shaft and the winding element. This relative position e.g. is needed to thread the yarn by means of an automatic threading device without further checking the rotary position of the winding element, or to adjust the winding element into a position in which a manual threading process can be carried out without problems. Additionally or alternatively, the information by which during the permanent vector control of the rotor rotation is followed can be used to measure the wound on yarn length. The capacity of the microprocessor is sufficient without problems for this additional function. No sophisticated additional control circuits are needed, and also no costly sensor assemblies.
[0009] The motor, expediently, is a permanent magnet motor which is available for fair costs and is efficient and takes up only minimal mounting space. Basically, however, also other types of synchronous motors may be used within the scope of this invention, like e.g. so-called reluctance motors, so even so-called “switched reluctance motors (SR)”. In principle, even a so-called BLDC (brushless DC motor) could co-operate with the speed control device according to the invention.
[0010] In order to be able to permanently (continuously) and precisely follow the movement of the rotor, it is of advantage when the permanent magnets in the rotor are designed (e.g. formed), magnetised and/or configured (placed) such that the backward acting electromotoric force induced by the rotor in the stator winding follows a sinusoidal course. With the help of the sinusoidal course the respective rotor rotary position can be calculated accurately which is of advantage for the permanent (continuous) vector control, and which is very suitable as a side product also for the position control and/or position observation of the winding element relative to the housing.
[0011] A calculating circuit is, expediently, contained in the speed control device, preferably in a microprocessor, which calculates the relative rotor rotary position with the help of the induced backwards oriented electromotoric force. The electromotoric force can be measured precisely in terms of its course and its magnitude.
[0012] Additionally, if expedient, at least one rotary position sensor may be provided and connected to the speed control device. The signal of this sensor may be used in order to build up a holding torque by means of the motor control and to retain the winding element at the predetermined rotary position relative to the housing despite an externally acting rotary force, and in order to retrieve the rotary position of the winding element or the rotor, respectively, during a restart of the motor.
[0013] Expediently, several relative rotary positions of the winding element within a 360° rotation of the winding element are programmed and can be selectively adjusted for correspondingly control stopping of the motor. That means that the winding element as well is stopped in the most suitable rotary position depending on the planned auxiliary function at the yarn feeding device. This relative rotary position can be selected completely arbitrarily.
[0014] It is expedient to place the stator part in a predetermined rotary position in the housing. By this measure each desired relative position of the winding element, as e.g. programmed, can be set in relation to the housing already during assembly of the yarn feeding device, without the necessity to carry out further programming.
[0015] By means of the determined permanent relative rotary position of the rotor during the vector control even the rotary travel of the winding element at least from the start to the end of a driving period can be measured without additional equipment parts, e.g. in order to precisely measure the wound on yarn length.
[0016] Alternatively, the yarn length may be measured in the same fashion even between selected points in time or selected different relative rotary positions of the rotor, respectively, by evaluating the information about the momentary rotor rotation angle for this additional function.
[0017] A predetermined relative rotary position of the winding element in relation to the housing may be a full yarn threading position in which an exit opening of the winding element is aligned with a threading path provided in the housing of the yarn feeding device. The on-board pneumatic threading device then may thread a new yarn without further interference by an operator.
[0018] Alternatively, the predetermined rotary position of the winding element in relation to the housing and adjustment by means of the vector control may be a semi-threading position in which an exit opening of the winding element is positioned outside of shielding housing parts such that no obstacles hinder the manual gripping of the yarn e.g. for knotting the yarn to yarn material already provided on the storage surface, or such that the winding element does not have to be rotated manually into a position beneficial to this auxiliary function.
[0019] An electronic yarn length measuring device can be supplied with the information on the rotor rotary positions during the vector control in order to e.g. derive precise information on the yarn consumption.
[0020] In the case that additionally a position sensor for the winding element is provided in the yarn feeding device, e.g. in order to signal at least one position or to confirm a position, respectively, then this position sensor may be used for generating an aligning holding torque by means of the motor and in co-action with the speed control device. The holding torque retains the winding elements in the adjusted rotor position even if external forces tend to further rotate the winding element. The motor control is apt to adapt automatically to the magnitude of the acting external force in order to hold the winding element stationary.
[0021] Expediently, the position sensor comprises permanent magnets distributed along the circumference of the winding element, and at least one detecting element fixed to the housing which responds to the passage of each permanent magnet. Preferably, a digitally operating Hall element is provided generating a digital signal whenever a permanent magnet is passing. However, particularly expedient is also an analogously operating Hall sensor responding respectively to one pair of adjacent permanent magnets in order to precisely monitor even rotation ranges of the winding element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] An embodiment of the invention will be explained with reference to the drawings wherein:
[0023] FIG. 1 is a longitudinal section of a yarn feeding device comprising a synchronous electric motor of a permanent magnet type as a driving source for a winding element, and
[0024] FIG. 2 is a cross-section of the yarn feeding device.
DETAILED DESCRIPTION
[0025] A yarn feeding device F as shown in FIG. 1 and FIG. 2 e .g. is a weft yarn feeding device for a weaving machine (not shown). However, the invention can be applied to a yarn feeding device for a knitting machine (not shown) as well, the yarn feeding device e.g. then having a rotary yarn storage drum defining a winding element.
[0026] The yarn feeding device F in FIGS. 1 and 2 comprises a housing 1 with a housing bracket 2 containing additional components. A hollow shaft 3 is rotatably supported in a bearing 4 in the housing 1 . The shaft 3 stationarily supports by its free end a storage drum D which is positioned below the housing bracket 3 . In order to prevent that the storage drum D rotates together with the shaft 2 permanent magnets 12 are provided in the housing which magnetically co-act with not shown permanent magnets placed in the storage drum D.
[0027] A rotor R is provided on the shaft 3 . The rotor co-acts with stator part S stationarily placed in the housing. The stator S is fixed by a positioning means 13 ( FIG. 2 ) in a predetermined rotary position.
[0028] An electric motor control device CU containing a microprocessor MP e.g. is contained in the housing bracket 2 . The motor control device CU is connected for signal transmission to a yarn sensor assembly 8 and controls the speed, the torque and the rest periods of the electric motor M e.g. depending on the size of a yarn store formed by yarn windings on the storage drum D. Furthermore, a yarn threading path 9 is provided in the housing bracket 2 for co-action with a not shown, on-board pneumatic threading device in order to thread a new yarn entirely through the yarn feeding device. Furthermore, a withdrawal opening 7 for the yarn is placed at the housing bracket 2 .
[0029] A winding element W having an exit opening 6 is fixed to the shaft 3 . The relative rotary position of the exit opening with respect to the rotor R is structurally fixed. The winding element W may be formed as a funnel-shaped disk 10 containing a not shown winding tube terminating at the exit opening 6 . At the winding element W permanent magnets 11 may be provided which are distributed along the circumference and which co-act with a detecting element H stationarily provided in the housing bracket 2 , e.g. with a digital or an analogous Hall sensor.
[0030] The electric motor M is an electric synchronous motor, preferably a permanent magnet motor (a so-called PM-motor). FIG. 2 illustrates the geometric distribution of permanent magnets PM in the rotor R and a schematic view of the stator part S (without stator windings provided therein).
[0031] With the help of the speed control device CU and the microprocessor MP a permanent vector control of the motor M is carried out, i.e., the rotary position of the rotor vector is determined continuously without sensors, and the stator vector is rotated by a corresponding current actuation continuously such that the desired speed and an optimum development of the torque result. The actuation of the stator windings is carried out sinusoidally. The permanent magnets PM in the rotor R are designed (formed), magnetised and/or configured (placed) such that, furthermore, forced by the function, the backwards oriented electromotoric force in the stator windings resulting from the rotation of the rotor R in relation to the stator parts S will be induced with a sinusoidal course. With the help of the sinusoidal course of the induced electromotoric force the rotary position of the rotor vector is continuously determined. The stator vector is rotated according to the determination by actuation of the stator part. The information about the momentary rotary position of the rotor vector or the rotor, respectively, in relation to the stator windings or the stator part S, respectively, and the housing, furthermore is used for the position control and/or the position observation of the winding element W.
[0032] Referring to FIG. 2 a predetermined rotary position X 1 of the winding element W is a so-called full threading position in relation to the housing 1 . In this full threading position the exit opening 6 of the winding element W is precisely aligned with the threading path 9 structurally integrated into the housing bracket 2 . In this predetermined rotary position X 1 the yarn while blown through the shaft 3 and out of the exit opening 6 is guided along the threading path 9 and finally is brought into the exit opening 7 without manual interference. However, a prerequisite for this function is that the winding element is stopped precisely at the predetermined rotary position X 1 when the electric motor M is stopped. For adjusting this rotary position X 1 now the permanently (continuously) present information on the rotary position of the rotor R in relation to the stator parts S or the housing, respectively, is used to precisely stop the winding element W at the predetermined rotary position X 1 by means of the speed control device CU, e.g. in case of a yarn breakage, as detected by not shown detectors.
[0033] In FIG. 2 , furthermore, a further predetermined rotary position X 2 is shown for the exit opening 6 of the winding element W. The rotary position X 2 is predetermined such that the exit opening 6 e.g. is stopped offset by 90° in relation to the housing bracket 2 , i.e. that the exit opening is not covered by any housing components hindering direct access.
[0034] In case that a not shown yarn detector detects a yarn breakage situation while yarn material is still present on the storage surface of the storage drum D, the winding element will be stopped in the rotary position X 2 by means of the vector control of the electric motor M such that the then activated pneumatic threading device will present the blown-through yarn at an easily accessible position of the housing for being gripped by the operator. By a corresponding re-correlation of the signal generated by the yarn detectors the speed control device CU will have been informed beforehand in which of the e.g. two predetermined positions X 1 , X 2 the yarn winding element W has to be adjusted for a certain operating condition.
[0035] The rotary position sensor 11 , H does not need to be used for this task. However, this sensor may assist, e.g. in order to prevent a undesired rotation of the winding element W when stopped at the respective position X 1 or X 2 , respectively. This means that then the speed control device CU will build a holding torque in the one or the other sense of rotation in order to locally retain the winding element despite the influence of external forces (the yarn tension or the like). Furthermore, the rotary position sensor 11 , H may be used for determining the rotary position of the rotor R and at the same time of the winding element W in case of a new operation start-up and as rapidly as possible.
[0036] Furthermore, a yarn length measuring device can be interlinked with the speed control device CU in order to measure the length of the wound on yarn by means of the rotary travel Y of the winding element W.
[0037] The respective predetermined rotary position X 1 , X 2 may be selected and adjusted arbitrarily, because the control permanently follows the movement of the rotor during operation of the motor and since the respective position information is present continuously. This means that neither the rotary positions X 1 , X 2 , nor further rotary positions of the winding element W as needed for other purposes have to be fixed beforehand either by the geometric relations between the stator S and the rotor R or by the geometric placement of the position sensor 11 , H. To the contrary any rotary positions can be freely adjusted or programmed, respectively, as they are best for the auxiliary functions of the yarn feeding device, e.g. for threading processes. The predetermined position X 2 e.g. even can be varied later by corresponding reprogramming, e.g. in a case in which at a weaving machine several yarn feeding devices have to be placed close to each other such that they might block the respective access e.g. to the position X 2 in FIG. 2 . In such a case the position X 2 can be put to another location where comfortable access is possible for the operator despite the restriction by the several closely arranged yarn feeding devices.
[0038] Although a particular preferred embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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The invention relates to a yarn feeding device (F) for weaving or knitting machines whose winding element (W) is driven by an electric motor (M) controlled by an electronic speed control device (CU). According to the invention, the electric motor (M) is a synchronous motor, in particular, a permanent magnet (PM) motor with the speed control device (CU) provided for effecting a permanent vector control with the stator being sinusoidally acted upon. Continuously determined information pertaining to the relevant rotational position of the rotor (R) of the motor (M) is used in the speed control device (CU), which serves to perform permanent vector control, in order to adjust at least one predetermined rotational position (X 1, X 2 ) of the winding element (W).
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CROSS-REFERENCE TO RELATED APPLICATION
This is a divisional of U.S. patent application Ser. No. 10/216,482, filed Aug. 8, 2002, now U.S. Pat. No. 6,928,728.
TECHNICAL FIELD
The present invention relates to utility meter registers used in moist environments.
DESCRIPTION OF THE BACKGROUND ART
In the field of utility metering, the actual metering device (the “meter”) is a different mechanism than the counting and display device which shows a total to the user or customer. This counting and display device is called a “meter register.” Traditionally, these meter registers have been mechanical devices, with a tabulating mechanism and with a dial or an odometer for displaying units of consumption for a utility, such as water, electric or gas. The meter register is mounted on or in close proximity to the meter to provide a local display of a consumption total.
Today, there are at least two types of water meter registers, a basic stand-alone type that is designed to be viewed directly, and a pulse-generating type, which in addition to providing a local visual display, also transmits pulses representing units of consumption to other remote displays and to data collection and monitoring devices.
In the basic type of meter register, an ethylene propylene gasket is assembled between a glass portion and a metal base portion to form a seal. In Walding et al., U.S. Pat. No. 5,734,103, an improvement is disclosed for the pulse-type meter register which uses an epoxy-based adhesive to join a glass lens portion to a metal base portion. The pulse-type register includes wires which exit the unit for connection to a remote display or monitoring unit, whereas the basic register does not include such wires and presents a simpler case for sealing.
In the southern United States, utility meters are often located outside of residential buildings, sometimes in subsurface enclosures. During rainy periods, these units may be subjected to extreme moisture conditions, and even submersion under water. There remains a need to provide a suitable seal in these conditions, such as offered by the epoxy sealing system described above, but at a lower cost of manufacture.
Therefore, there remains a need for better sealing methods and structures for meter registers and better methods of manufacture and assembly of these units.
SUMMARY OF THE INVENTION
The invention is incorporated in an instrument assembly comprising a base and a lens which is at least transparent in part, to enclose an instrument works, while allowing a view to the interior. An annular body forms a seal between the base and lens. The sealant is flowed into position in a channel formed by the base around the perimeter of the instrument works. The lens has a lower edge pressed into the body of sealant, which is a hot melt butyl rubber that has been cured within the channel.
The flowed body of butyl rubber has been found to provide a better vapor seal than the gasket and a lower cost of manufacture than the epoxy-based system of the prior art.
The invention is further practiced in a method of providing a water vapor seal and mechanical bond between a lens and a base comprising: heating the lens and the base to at least approximately 180 degrees F.; heating an instrument works to a temperature of at least approximately 140 degrees F.; assembling the instrument works and the base, such that a groove is formed around the instrument works; maintaining a level of heating for the assembly of the instrument works and the base, such that the base is at a temperature of at least approximately 250 degrees F. in the channel; dispensing a heated body of sealant into the channel to form a ring of sealant; assembling the lens to the base and pressing a lower edge of the lens into the ring of sealant; and allowing the sealant to cure.
In contrast to the prior art, the above method provides for preliminary heating of the components to provide better results in forming the lens-to-base seal.
As a further aspect of the invention, it is advantageous to bend over a portion of an edge of the base to form a lip which helps hold the sealant in place and helps hold the assembly together.
The invention can be applied to a local utility meter register and to a pulse-generating meter register in which at least two signal conductors penetrate the housing. In the second case, an overlap point for the bead of sealant is spaced from the entry points to isolate possible causes of leakage.
Other objects and advantages of the invention, besides those discussed above, will be apparent to those of ordinary skill in the art from the description of the preferred embodiments which follows. In the description, reference is made to the accompanying drawings, which form a part hereof, and which illustrate examples of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of a basic meter register incorporating the present invention;
FIG. 2 is a longitudinal section view taken in the plane indicated by line 2 - 2 in FIG. 1 ;
FIG. 3 is perspective view of a step in manufacturing the basic meter register of FIG. 1 ;
FIG. 4 is a top plan view of FIG. 3 rotated by 90 degrees;
FIG. 4 a is a sectional detail view taken in the plane indicated by line 4 a - 4 a in FIG. 4 ;
FIG. 4 b is a sectional detail view taken in the same plane as FIG. 4 a;
FIG. 5 is a bottom plan view of a forming head used in manufacturing the meter register of FIG. 1 ;
FIG. 6 is a side view in elevation of the forming head of FIG. 5 ;
FIG. 6 a is a detail sectional view taken in the location indicated by line 6 a - 6 a in FIG. 6 ;
FIG. 7 is a second embodiment of a meter register of the present invention;
FIG. 8 is a longitudinal section view taken in the plane indicated by line 8 - 8 in FIG. 7 ;
FIG. 9 is a detail sectional view from the bottom of a grommet area in the embodiment of FIG. 8 ; and
FIG. 10 is a flow chart of the manufacturing process for making the embodiments of FIGS. 1 and 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a first embodiment of a local meter register assembly 10 that incorporates the present invention. The device is called “local” because it provides a view of consumption units only at the location of the device. The register 10 includes a transparent, dome-shaped lens 11 for viewing an instrument face 12 . Preferably this lens is made of glass, but plastic and other materials could be used as long as a transparent portion or window is provided. A dial hand 13 is pivotally connected at the center of the instrument face 12 , and indicia 14 are provided around a periphery of the instrument face 12 . An odometer 15 is positioned below the dial pivot point. The odometer 15 includes a plurality of number wheels 16 for respective digits. The odometer 15 is viewed through an aperture 28 in the instrument face 12 as seen best in FIG. 2 .
FIG. 2 illustrates that the lens 11 is joined to a base 17 by a body of sealant 18 to form an enclosure for the assembly 10 . The base is made of metal, with materials such as copper, a brass or a copper alloy being preferred, but other metals, such as tin alloys or aluminum alloys could be used and other materials such as resinous synthetic materials, glass or ceramics could be used. Inside the enclosure formed by the lens 11 and the base 17 is an instrument works assembly 19 , which is supported by a plastic base 20 and a chassis 21 . The instrument works 19 provides a mechanical counting mechanism. Also seen is a magnetic pickup wheel 22 which rotates in response to movement of a water turbine in a meter housing (not shown). The rotations are coupled through a mechanical drive train 23 in the instruments works 19 to drive the dial hand 13 and the odometer 15 .
The sealant 18 ( FIG. 2 ) to be used for providing a seal between the glass lens 11 and the metal base 17 is a butyl rubber sealant, such as Delchem D-2000. This sealant has an approximate viscosity of 300,000 Centipoise (CPS) at 400 degrees F. The sealant is thick and sticky, thicker than peanut butter at room temperature. The metal base 17 is made of “red brass” which has a relatively high copper content. A base 17 of this material has a tendency to draw heat out of the butyl rubber after it is applied to the base 17 . As the sealant cools, the viscosity increases, making it thicker. For proper flow, adhesion and curing, the sealant should be applied after being heated to approximately 380 degrees F.
In assembling the meter register 10 seen in FIG. 2 , there are three main subassemblies, the lens 11 , the base 17 and the instrument works 19 . FIG. 10 shows the steps in assembling and sealing the assembly 10 . After the start of the process, represented by start block 80 , the components 11 , 17 and 19 are preheated, as represented by process block 81 . This helps in preserving the heat of the dispensed bead of sealant 18 . The dispensing equipment is also set up to transfer heat into the sealant, all the way through the system, and into a channel formed to receive the sealant.
The glass lens 11 is preheated in an oven to 300 degrees F. to get adhesion strength, to promote a homogeneous overlap point, and cause the butyl rubber to flow into a channel in the register assembly. The base 17 is preheated in the same oven as the glass to a temperature of 300 degrees F. The register works assembly 19 is preheated in a separate oven to 140 degrees F.
After preheating for a suitable time, the base 17 and register works assembly 19 are removed from the ovens, and assembled as represented by process block 82 in FIG. 10 . A heated metal base 17 and a heated register works 19 are manually brought together and assembled outside of the ovens to form the assembly seen in FIGS. 3 and 4 . During this time, the temperature of the base 17 may drop below 200 degrees F.
The assembly seen in FIGS. 3 and 4 is placed in a heated holder as represented by process block 83 in FIG. 10 . In the preferred embodiment, the holder is heated by induction heating. Because the works assembly 19 includes plastic parts, and heat can be transferred from the base 17 during assembly, the metal base 17 is maintained at only approximately 250 degrees F. during its time in this holder. This is sufficient to preserve the integrity of the butyl sealant, keeping it soft and pliable for the hot glass to make a homogeneous interface, particularly at the overlap point where the two ends of the bead of sealant meet.
Before dispensing a bead of sealant 18 , as seen in FIGS. 3 and 4 , the butyl rubber material is heated in zones to 380 degrees F. as represented by process block 84 in FIG. 10 . Next, a bead of sealant 18 is applied to a channel 25 ( FIG. 3 ) formed between the base 20 and side wall 17 a , while the sealant is heated, as represented by process block 85 in FIG. 10 . It should be noted that while the cross section of the channel is generally rectangular, the use of the term “channel” herein encompasses grooves and channels of various available cross sections, and is not limited to rectangular cross sections. In dispensing the bead in FIG. 3 , the dispensing nozzle 24 is fixed in its position and the assembly 17 , 19 is rotated (in the direction of the arrow) to create the bead 18 .
The nozzle 24 utilizes a heavy-wall, high mass, beryllium copper material for maintaining the sealant 18 at the temperature of 380 degrees F. as it is laid down in a circular bead as seen in FIG. 3 . The bead is dispensed into a channel 25 formed between base 20 of the instrument works 19 and a side wall 17 a of the metal base 17 . The sealant 18 is pumped through a nozzle 24 using a gear pump driven by a servomotor. A shot size is programmed to correspond the volume of sealant 18 necessary to make the ring-shaped bead of sealant 18 . The dispensing of sealant 18 will be turned off when the nozzle 24 reaches an end point.
Backpressure is created by dispensing a large bead 18 with the tip 24 a as close to the channel 25 as possible without bottoming the tip 24 a . Clearances are held as close as 0.020 inch from tip 24 a to the side wall 17 a and to the edge of the base 20 . Backpressure causes the dispensed bead to have a bulb 26 ( FIG. 4A ) that travels in front of the nozzle tip 24 a as the assembly is rotated to create the bead 18 . It is this bulb 26 that makes the start and stop interface overlap and a homogeneous blend of the start and stop points for the nozzle. The bulb 26 at the stop end is able to push its way under, into and over the start end 27 of the bead 18 , when the bead is finished at the end of the dispensing cycle ( FIG. 4B ). The formation of a homogenous overlap point is critical to successful sealing.
After the sealant 18 has been dispensed into the assembly 17 , 19 , as a ring-shaped body, the glass lens 11 is assembled as represented by process block 86 in FIG. 10 . The glass lens 11 is inserted, such that a bottom edge 11 a of the glass lens 11 contacts the overlap point first. The glass lens 11 is angled into the sealant 18 at the overlap point, and then the angle is reduced to zero as the glass lens 11 is brought into contact with the body of sealant over 360 degrees. In this way, the overlap point is made homogeneous due to the heat and pressure transferred to the overlap point through the glass lens 11 .
Next, as represented by process block 87 in FIG. 10 , the assembly is removed from the heated fixture and placed in a forming machine. The forming machine has a rotating head 30 , seen in FIGS. 5 and 6 . The head 30 rotates around an axis of rotation 32 and supports three forming wheels 31 a , 31 b and 31 c . The wheels 31 a - 31 c each have a niche 33 that receives the top edge 17 b of the side wall 17 a and rolls the edge over the lip 11 b of the glass lens 11 as the wheels 31 a - 31 c roll around the top edge 17 b of the base 17 . During this operation, the forming head 30 also presses the glass lens 11 further into the body of sealant 18 .
Next, as represented by process block 88 in FIG. 10 , the assembly is removed from the forming machine and set aside for cooling. Cooling takes approximately thirty minutes. When the sealant 18 reaches room temperature, the hot melt properties of the sealant have been cured. In approximately three to five months, the reactive components of this material are fully cured by way of reactions with moisture. In three to five months, the material has reached ultimate properties and no further curing can occur. This completes the process for the local register as represented by end block 89 .
Referring to FIGS. 7 and 8 , a meter register assembly 40 of the pulse-transmitting type is shown. This register 40 has a glass lens 41 , dial face 42 , dial hand 43 , indicia 44 , odometer 45 , number wheels 46 , a metal base 47 , an instrument works 49 and other parts similar to the local meter register 10 , except for additional parts to be described. In this register 40 , a magnetic pickup 52 drives a cam which operates a piezoelectric-based pulse-generating element of a type known in the art. The electrical pulses represent units of consumption. These are transmitted through two insulated wires 55 to remote displays and to remote data collection and utility usage monitoring equipment. The wires 55 have portions 57 inside the base side wall 47 a ( FIG. 9 ) which are stripped of insulation where the sealant 58 will contact them, to provide a better vapor seal around the wire entry points to the assembly 40 than would be provided by the wire insulation.
A grommet 54 ( FIG. 9 ) supports the wires 55 as they enter the register 40 . The grommet 54 has a flange and groove portion 56 for anchoring the grommet 54 in a side wall 47 a of the metal base 47 . The grommet 54 has holes 62 through its body from the inside to the outside of the register 40 with a spacing of at least 0.164 inches to receive the two wires 55 . This spacing is greater than in the prior art and is necessary to allow enough space for the sealant 58 to flow in and around the wires 55 . No other holes or vents in the grommet are necessary. The process of assembling and sealing this assembly follows the process of FIG. 10 , with the following differences. Because the wires 55 must exit the assembly through side wall 47 a of the base 47 , the register works assembly 49 , the plastic instrument base 50 and the metal register base 47 are assembled as represented by process block 82 before being heated as represented by process block 81 in FIG. 10 .
Another difference is that the start point 59 for the sealant bead 58 is approximately three-eighths of an inch away from the stripped portions 57 of the wires 55 . The assembly 47 , 49 is rotated such that the stripped portions 57 of the wires 55 are rotated away from the stationary dispensing nozzle tip 24 a (in the direction of the arrow in FIG. 9 ). The stripped portions 57 of the wires 55 are covered near the end of the rotation with the overlap point being reached after crossing the wires 55 . This allows the base 47 to build-up heat as a result of time in the heated fixture and exposure to the hot sealant bead. This also places the overlap point at a different point than the wire entry points. This isolates the wire entry point from the overlap point so that these can be checked individually for leakage. If the bead is started and stopped over the wires, two possible leakage causes would be present in one location, which would make leakage problems more difficult to diagnose.
The heated glass lens 41 is pressed into the overlap point and wire entry points first, to create the best possible seal in those regions. Then, the glass lens 41 is angled into the remaining portion of the sealant 58 , as described previously.
All other operations were the same as described previously for FIG. 10 . By using a common process as described above, one dispensing machine system can accommodate two different assemblies, the local register and remote pulse-transmitter register, thus reducing set-up time, tooling and machine complexity.
This has been a description of the preferred embodiments of the invention. For embodiments falling within the spirit and scope of the present invention, reference is made to the claims which follow.
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A method and article of manufacture for providing a mechanical bond and an improved water vapor seal between a lens ( 11, 41 ) and a base ( 17, 47 ) in an instrument housing ( 10, 40 ), includes heating the components and a hot butyl rubber sealant ( 18, 58 ) prior to assembly, maintaining a level of heating for the assembly during assembly, dispensing the heated sealant ( 18, 58 ) into a channel ( 25, 65 ) to form a ring-shaped body of sealant ( 18, 58 ), assembling the lens ( 11, 41 ) to the base ( 17, 47 ) and pressing a lower edge ( 11 a , 41 a ) of the lens ( 11, 41 ) into the ring of sealant ( 18, 58 ) and bending an upper edge ( 17 b , 47 b ) of the side wall ( 17 a , 47 a ) over a portion ( 11 b, 41 b ) of the lens ( 11, 41 ). The method is applied in a second embodiment to an instrument having at least two signal conductors ( 55 ) entering the base ( 47 ) at two entry points. Apparatuses manufactured with the method are also disclosed.
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This application is a continuation of Ser. No. 10/155,020 filed May 28, 2002 now U.S. Pat. No. 6,872,390 which is a continuation of Ser. No. 09/852,751 filed May 11, 2001 now U.S. Pat. No. 6,432,401, which claims benefit of 60/203,800 filed May 12, 2000 and claims benefit of 60/235,855 filed 09/27/2000.
FIELD OF THE INVENTION
The invention is in the field of medicinal chemistry. The invention relates in particular to a method of reversing local anesthesia induced by a local anesthetic and an alpha-adrenergic agonist, comprising administering an effective low dose of an alpha-adrenergic antagonist.
RELATED ART
Local anesthesia is widely used by dentists to provide pain relief to patients during dental procedures. To provide pain relief, a drug formulation containing a local anesthetic compound such as lidocaine is injected into the gum tissue surrounding the tooth or teeth on which the dental procedure is to be performed. There are short-acting and long-lasting local anesthetic drug formulations. Short-acting local anesthetic drug formulations contain lidocaine or a related local anesthetic drug dissolved in saline or other suitable injection vehicle. Typically, local anesthesia with short-acting local anesthetics lasts approximately 20-30 minutes, which is not long enough for many dental procedures. To obtain long-lasting local anesthesia, dentists often use lidocaine or other local anesthetic formulations which, in addition to the local anesthetic drug itself, contain low concentrations of epinephrine or another adrenergic receptor agonist such as levonordefrin. More than 90% of the local anesthesia procedures performed by dentists involve local anesthetic formulations containing alpha-adrenergic receptor agonists. The vasoconstrictor is necessary because local anesthetics without vasoconstrictor are too short-acting for most dental procedures. The added epinephrine stimulates alpha-adrenergic receptors on the blood vessels in the injected tissue. This has the effect of constricting the blood vessels in the tissue. The blood vessel constriction causes the local anesthetic to stay in the tissue much longer, resulting in a large increase in the duration of the anesthetic effect (from 20 minutes for the short-acting formulation to 3-6 hours for the long-lasting formulation). A major problem with the use of epinephrine-containing local anesthetics is soft-tissue anesthesia (lip, cheek, tongue) which usually lasts many hours longer than anesthesia and analgesia of the tooth pulp. Tooth pulp anesthesia and analgesia are the desired effects of local anesthesia from a dental procedural perspective while soft-tissue anesthesia is usually an undesirable side effect. Soft tissue anesthesia results in a number of problems and inconveniences, such as a prolonged and uncomfortable feeling of numbness in and around the mouth, inability to smile, difficulty eating, drinking and swallowing, loss of productivity by missing work hours or meetings etc. Lingering soft-tissue anesthesia can be the cause of injuries due to biting of the tongue or lips. Lingering soft-tissue anesthesia can also result in loss of productivity due to missed work hours or meetings etc. Furthermore, lingering soft-tissue anesthesia is an inconvenience and it is perceived as an annoyance by many patients. Lingering soft-tissue anesthesia can lead to injury especially in children who often bite into the anesthetized tissue out of curiosity. It would therefore be desirable to have a drug that could be used at will by dentists to rapidly reverse local anesthesia after it is no longer needed
U.S. Pat. No. 4,659,714 discloses a method of prolonging local anesthesia by coadministering a vasoconstrictor, in particular, a vasoconstrictor that acts upon the alpha-adrenergic receptor sites of the blood vessel walls. The '714 patent also discloses the subsequent administration of an alpha-adrenergic receptor antagonist to cause reduction of the prolonged anesthesia effect. Included within the group of alpha-adrenergic receptor antagonists described in this patent are phentolamine mesylate. However, the examples make reference to the administration of “phentolamine.” It is much more likely that what was administered was phentolamine mesylate since phentolamine mesylate is FDA approved and readily soluble in water. In contrast, phentolamine is not FDA approved and is relatively insoluble in water.
As shown in Example 1, Table 1, 0.5-1.5 mg of “phentolamine” was administered to groups of patients which were pretreated with lignocaine admixed with epinephrine. The results in Table 1 show a reduction in the duration of anesthesia with increasing amounts of “phentolamine.” In Example 2, 2 mg of “phentolamine” was administered. In Example 3, four injections of 1 mg each (4 mg total) of “phentolamine” were administered. In Example 4, four injections of 1 mg each (4 mg total) of “phentolamine” were administered.
The drug doses of “phentolamine” described in the '714 patent (0.5-4 mg) overlap the doses of phentolamine mesylate that are approved by the FDA for the systemic treatment of high blood pressure in patients with pheochromocytoma (total dose of 5 mg in a solution of 2.5-5 mg/ml). Since those doses are normally intended for systemic treatment of high blood pressure, those high dose levels can cause severe side effects when used in healthy, normal people. The package insert of the phentolamine-mesylate product states the following side effect warning: “Myocardial infarction, cerebrovascular spasm, and cerebrovascular occlusion have been reported to occur following the administration of phentolamine, usually in association with marked hypotensive episodes.” Thus, the drug doses taught by the '714 patent for the reversal of local anesthesia may cause unacceptable side effects, precluding the use of this product for anesthesia reversal in healthy normal subjects in a dentist's office.
It has now been discovered that a highly effective local anesthesia reversal can be obtained by injections of much lower concentrations of phentolamine-mesylate than is disclosed in the '714 patent. It has been found that a solution containing only 0.05 mg/ml of phentolamine-mesylate can rapidly reverse the effect of a local anesthetic containing an alpha adrenergic receptor agonist. This phentolamine-mesylate drug concentration is 20-100 times lower than the phentolamine-mesylate drug concentration taught by the '714 patent. The advantage is that, at such low phentolamine-mesylate drug concentrations, no systemic side effects such as myocardial infarction and cerebrovascular spasm will be observed. This allows the safe and effective use of phentolamine-mesylate for local anesthesia reversal without causing life-threatening or other untoward side effects. Indeed, in a human clinical efficacy study using a low-concentration-formulation of phentolamine-mesylate, a highly effective anesthesia reversal was observed without any side-effects whatsoever. Thus, this invention constitutes a crucial improvement of the local anesthesia reversal method taught by the '714 patent.
SUMMARY OF THE INVENTION
The present invention provides compositions and formulations of low concentrations of phentolamine-mesylate and other alpha adrenergic receptor antagonists and use thereof for reversing the effects of long-lasting local anesthetic agents containing alpha-adrenergic receptor agonists.
In particular, the invention relates to a method of providing local anesthesia to a mammal, comprising:
(a) administering to the mammal in need thereof an anesthetic agent and an alpha adrenergic receptor agonist to the site to be anesthetized, wherein said anesthetic agent is administered in an amount effective to provide local anesthesia and said alpha adrenergic receptor agonist is administered in an amount effective to constrict the blood vessels at the site and prolong the local anesthesia, and then
(b) administering a low dose of an alpha adrenergic receptor antagonist to said site to reduce the prolongation.
In a preferred embodiment, the invention relates to a method of providing local anesthesia to a human, comprising:
(a) administering to a human in need thereof by injection to the site to be anesthetized a solution comprising polocaine and levonordefrin, wherein said polocaine is administered in an amount effective to provide local anesthesia and said levonerdefrin is administered in an amount effective to constrict the blood vessels at the site and prolong the local anesthesia, thereby producing local anesthesia at said site,
(b) carrying out a medical procedure on the human, and then
(c) administering phentolamine mesylate at said site at a concentration of about 0.05 mg/ml or less to reduce the prolongation.
The invention also relates to a method of enhancing the survival of a tissue graft, comprising
(a) administering to a mammal undergoing a tissue graft an anesthetic agent and an alpha adrenergic receptor agonist to the site of the tissue graft, wherein said anesthetic agent is administered in an amount effective to provide local anesthesia and said alpha adrenergic receptor agonist is administered in an amount effective to constrict the blood vessels at the site and prolong the local anesthesia,
(b) performing the tissue graft procedure, and then
(c) administering an alpha adrenergic receptor antagonist to said site to reduce the prolongation and enhance the tissue graft survival.
The invention also relates to a method of providing a regional anesthetic block to a mammal, comprising:
(a) administering to the mammal in need thereof an anesthetic agent and an alpha adrenergic receptor agonist in the site to receive the anesthetic block, wherein said anesthetic agent is administered in an amount effective to provide local anesthesia and said alpha adrenergic receptor agonist is administered in an amount effective to constrict the blood vessels in the site and prolong the anesthetic block, and then
(b) administering an alpha adrenergic receptor antagonist to said site to reduce the prolongation.
The invention also relates to a kit comprising a carrier means having in close confinement therein two or more container means, wherein a first container means contains an anesthetic agent and optionally an alpha adrenergic receptor agonist and a second container means contains a low dose of an alpha adrenergic receptor antagonist.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention relates to a method of providing local anesthesia to a mammal, comprising:
(a) administering to the mammal in need thereof an anesthetic agent and an alpha adrenergic receptor agonist to the site to be anesthetized, wherein said anesthetic agent is administered in an amount effective to provide local anesthesia and said an alpha adrenergic receptor agonist is administered in an amount effective to constrict the blood vessels at the site and prolong the local anesthesia, and then
(b) administering a low dose of an alpha adrenergic receptor antagonist to said site to reduce the prolongation.
The anesthetic agent and alpha adrenergic receptor agonist may be administered together as part of a unitary pharmaceutical composition or as part of separate pharmaceutical compositions so long as the alpha adrenergic receptor agonist acts to constrict the blood vessels in the vicinity of where the anesthetic agent has been administered to result in a prolonging of anesthesia. In a preferred embodiment, the anesthetic agent and alpha adrenergic receptor agonist are administered together in solution. The anesthetic agent and alpha adrenergic agonist may be administered by injection, by infiltration or by topical administration, e.g. as part of a gel or paste.
In a preferred embodiment, a solution comprising the anesthetic agent and alpha adrenergic receptor agonist is administered by injection directly into the site to be anesthetized, e.g. prior to a dental procedure.
Examples of local anesthetics that may be used in the practice of the invention include without limitation lidocaine, polocaine, lignocaine, xylocaine, novocaine, carbocaine, etidocaine, procaine, prilocaine, bupivacaine, cinchocaine and mepivacaine.
Examples of alpha adrenergic receptor agonists that can be used according to the invention include catecholamines and catecholamine derivatives. Particular examples include without limitation levonordefrin, epinephrine, and norepinephrine.
Examples of alpha adrenergic receptor antagonists that can be used in the practice of the invention include without limitation phentolamine, phentolamine hydrochloride, phentolamine mesylate, tolazoline, yohimbine, rauwolscine, doxazosine, labetolol, prazosine, tetrazosine and trimazosine. Phentolamine-mesylate is approved by the FDA for the treatment of hypertension in patients with pheochromocytoma, for the treatment of dermal necrosis and sloughing following accidental extravasation of norepinephrine, and for the diagnosis of pheochromocytoma (phentolamine blocking test). The drug is supplied in vials containing 5 mg of drug substance which may be dissolved in physiological saline or other pharmaceutically acceptable carrier.
In order to reverse the local anesthesia after a medical procedure according to the present invention, the alpha adrenergic receptor antagonist is administered at a low dose, i.e. at a dose that does not cause side effects, i.e. at or below about 0.25 mg per dose for adults (at or below about 0.0036mg/kg) or 0.1 mg per dose for children, more preferably, below about 0.1 mg per dose for adults (below about 0.0014 mg/kg) or 0.04 mg per dose for children, most preferably, at about 0.08 mg per dose for adults (about 0.0011 mg/kg) or about 0.032 mg per dose for children, of phentolamine mesylate or a molar equivalent of another adrenergic receptor antagonist. In a preferred embodiment, the alpha adrenergic receptor antagonist is present at a concentration of from about 0.001 mg/ml to about 0.25 mg/ml, more preferably, about 0.05 mg/ml to about 0.1 mg/ml.
The alpha adrenergic receptor antagonist may be administered by injection into the site of anesthesia, by infiltration or by topical administration. In a preferred embodiment, the alpha adrenergic receptor antagonist is administered to mucosal tissue. In this embodiment, the alpha adrenergic receptor antagonist may be applied to the site in the form of an impregnated wafer, pellet or cotton ball, whereby the antagonist is taken up by the mucosal tissue resulting in reversal of the anesthesia. In another embodiment, the alpha adrenergic receptor antagonist is administered to the site of a regional anesthetic block to reverse the block, e.g. by injection or infiltration into the site. In a preferred embodiment, the alpha adrenergic receptor antagonist is administered via a cannula into the epidural space of an animal to reverse epidural anesthesia.
Examples of medical procedures that may be carried out according to the present invention include, without limitation, both major and minor surgery, dental procedures, cosmetic surgery, tissue grafting (e.g. hair and bone grafting) and cesarean section. In one embodiment, reversal of anesthesia according to the present invention is carried out by medical trainees to mitigate any mistakes that are made, and which may lead to the loss of extremities such as fingers, as well as ears and tips of noses.
Hyaluronidase, an enzyme which enhances the diffusion of drugs within tissues, may be administered together with the alpha adrenergic receptor antagonist. The hyaluronidase and alpha adrenergic receptor antagonist may be administered together as part of a unitary pharmaceutical composition or as part of separate pharmaceutical compositions, so long as the hyaluronidase and alpha adrenergic receptor antagonist are administered to the site where anesthesia is to be reversed and are present in amounts effective to enhance the diffusion of the alpha adrenergic receptor antagonist and to reverse the anesthesia, respectively. The hyaluronidase is administered one or more times into the site of anesthesia. In general, about 1.5 U to about 200U of hyaluronidase is administered in one or more injections. In a most preferred embodiment, about 200 U of hyaluronidase is administered by injection into the site. Those of ordinary skill in the art can determine optimal amounts of hyaluronidase with no more than routine experimentation.
When performing hair grafts, the surgeon often injects an anesthetic and epinephrine to reduce bleeding and provide a clear vision of the site. According to Bernstein, R. M. and Rassman, W. R., Hair Transplant Forum International 10:39-42 (2000), the usefulness of epinephrine in hair graft procedures is limited by a number of factors including post-operative telogen effluvium when epinephrine is used in large transplant sessions. In addition, when adrenaline is added to an area whose blood supply is already compromised by a large number of recipient sites, the tissue may not receive enough oxygen. Although not proven, according to Bernstein and Rassman it is likely that epinephrine infiltration into the recipient area is a contributing factor in the development of the “central necrosis” that has occasionally been reported during hair transplantation. Furthermore, it is possible that the intense vasoconstrictive action of epinephrine may contribute to the decreased graft survival. Thus, according to the present invention, one may achieve enhanced tissue graft survival in a method comprising
(a) administering to a mammal undergoing a tissue graft an anesthetic agent and an alpha adrenergic receptor agonist to the site of the tissue graft, wherein the anesthetic agent is administered in an amount effective to provide local anesthesia and the an alpha adrenergic receptor agonist is administered in an amount effective to constrict the blood vessels at the site and prolong the local anesthesia,
(b) performing the tissue graft procedure, and then
(c) administering an alpha adrenergic receptor antagonist to said site to reduce the prolongation and enhance the tissue graft survival.
In a preferred embodiment, the tissue graft is a hair graft. In another preferred embodiment, a low dose of alpha adrenergic receptor antagonist is administered to the site to avoid untoward side effects.
Such hair grafts include skin flaps containing a plurality of hair cells and single transplanted hair cell follicles. Typically, such hair grafts are obtained from a site on the animal that has actively growing hair. According to the present invention, an alpha adrenergic receptor antagonist is administered after a hair graft procedure to reverse the local anesthesia and reduce post-operative telogen effluvium (shedding of hair) and survival of the skin flap.
In another embodiment, hyaluronidase may be administered to the tissue graft site to increase survival of the graft. According to Pimentel, L. A. S. and Goldenburg, R. C. d. S, Revista da Soociedade Brasileira de Cirurgia Plastica 14 (1999), the local administration of hyaluronidase increases skin flap survival. According to the authors, hyaluronidase is an enzyme that reduces or prevents tissue injury presumably by causing the rapid diffusion of extravasated fluids to distant areas, thus allowing a better turnover of nutrients. The hyaluronidase is generally injected one or more times into the site of the hair graft. Similarly, the present invention can be used to improve survival of other engrafted tissues or bone in any graft surgical procedure where a local anesthetic and an alpha adrenergic receptor agonist is used minimize bleeding during the surgery and where subsequent rapid reperfusion of tissue is desired in order to increase graft survival.
In a further embodiment, an alpha adrenergic receptor antagonist is administered after a regional anesthetic block to reverse the block. Epidural anesthesia is commonly administered to provide a regional anesthetic block in a number of medical procedures including child birth, cesarean section, surgery to the pelvis and the like. Prolonged epidural anesthesia has many untoward side effects, including prolonged paralysis, inability to voluntarily urinate, and hypotension. Typically, the anesthesiologist injects into the epidural space an equal volume of saline in an effort to dilute the anesthetic and reduce the anesthesia.
The present invention solves the side effect problems by providing for on demand reversal of the anesthesia without the need for injecting large volumes of saline. In this embodiment, the invention relates to a method of providing a regional anesthetic block to a mammal, comprising:
(a) administering to a mammal in need thereof an anesthetic agent and an alpha adrenergic receptor agonist in the site to receive the anesthetic block, wherein the anesthetic agent is administered in an amount effective to provide local anesthesia and the alpha adrenergic receptor agonist is administered in an amount effective to constrict the blood vessels in the site and prolong the local anesthesia, and then
(b) administering an alpha adrenergic receptor antagonist to the site to reduce the prolongation.
In a preferred embodiment, a low dose of the alpha adrenergic receptor antagonist is administered. In another preferred embodiment, the anesthetic block is epidural anesthesia and the site of the block is the epidural space. The invention has application to reversal of other blocks as well including brachial plexus and femoral blocks.
In another embodiment, hyaluronidase is administered together with the alpha adrenergic receptor antagonist to enhance the diffusion of the alpha adrenergic receptor antagonist within the site of the block, e.g. the epidural space, and speed reversal of the anesthesia.
The invention also relates to a kit comprising a carrier means such as a carton or box having in close confinement therein two or more container means such as carpules, vials, tubes, jars and the like. A first container means contains an anesthetic agent and optionally an alpha adrenergic receptor agonist and a second container means contains a low dose of an alpha adrenergic receptor antagonist. Alternatively, the alpha adrenergic receptor agonist may be present in a separate container means. A further container means may contain hyaluronidase. Alternatively, the hyaluronidase is in the same container means as the alpha adrenergic receptor antagonist. In a preferred embodiment, the anesthetic agent, alpha adrenergic receptor agonist, alpha adrenergic receptor antagonist and, optionally, the hyaluronidase are present in 1.8 mL carpules that fit into a standard dental local anesthetic syringe. Such carpules are available commercially from a variety of suppliers, e.g. Henry Schein, Port Washington, N.Y. In this embodiment, a carpule containing the local anesthetic and alpha adrenergic receptor agonists is placed into the syringe, and the mixture is injected. The carpule may then be removed and a second carpule inserted which contains the alpha adrenergic receptor antagonist and, optionally, the hyaluronidase.
The anesthetic agent, vasoconstrictor, alpha adrenergic receptor antagonist and, optionally, the hyaluronidase may be present in solution, preferably, a sterile solution, optionally containing salts and buffers, or as part of a gel or paste for topical administration. See U.S. Pat. No. 4,938,970 and Remington's Pharmaceutical Sciences, A. Osol (ed.), 16th Edition, Mack Publishing Co., Easton, Pa. (1980).
Mammals which may be treated according to the present invention include all mammals that may experience the beneficial effects of the present invention. Such mammals include without limitation humans and veterinary mammals such as cattle, pigs, sheep, horses, dogs, and cats. When applied to children and veterinary animals, the prompt reversal of anesthesia inhibits the child or animal from tearing open fresh sutures.
The following examples are illustrative, but not limiting, of the method and compositions of the present invention. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in clinical therapy and which are obvious to those skilled in the art are within the spirit and scope of the invention.
EXAMPLES
Study Rationale and Purpose
Local anesthesia is widely used by dentists to effect anesthesia during dental procedures. Local anesthetics often contain alpha-adrenergic receptor agonists to cause vasoconstriction thereby prolonging anesthesia. The vasoconstrictor is necessary because local anesthetics without vasoconstrictor are too short-acting for most dental procedures. On the other hand, in many instances the prolonged local anesthetic effect lasts much longer than required for many dental procedures. It would be desirable to have a drug that could be used at will to rapidly reverse local anesthesia after it is no longer needed. Lingering local anesthesia can be the cause of injuries due to biting of the tongue or lips. Lingering local anesthesia can also result in loss of productivity due to missed work hours. Lastly, lingering local anesthesia is an inconvenience and it is perceived as an annoyance by many patients. The purpose of the present study was to determine whether phentolamine-mesylate, an injectable alpha-adrenergic receptor agonist, which is FDA approved for the systemic treatment of hypertension in pheochromocytoma patients, rapidly reverses prolonged local anesthesia when injected locally at a very low concentration. The phentolamine-mesylate concentration chosen for the present study was so low that it would be expected to lack systemic side-effects such as severe episodes of hypotension that have been described with the high systemic drug doses which are approved by the FDA for the treatment of hypertension in pheochromocytoma patients.
Study Design
The present human subjects study was designed to determine whether injection of a physiological saline solution containing an extremely low concentration of phentolamine-mesylate is able to accelerate the reversal of the effects of a previously injected local anesthetic agent containing an alpha-adrenergic receptor agonist. An injection of the physiological saline vehicle (without phentolamine-mesylate) served as the control. In order to compare the effects of phentolamine-mesylate to the vehicle in the same patient, bilateral local anesthesia injections were made into the mouth of the same patient. This was followed by injection of the phentolamine-mesylate containing local anesthetic reversal agent (LARA) into one side of the oral cavity, and injection of the saline vehicle (control) solution into the opposite side of the oral cavity. The time to reversal of the local anesthetic effect on both sides was then recorded to determine whether there is a difference between the two sides.
Drugs
The local anesthetic used was 2% polocaine (mepivacaine hydrochloride) with levonordefrin (1:20,000=0.05 mg/ml) (levonordefrin injection, USP) (Astra USA, Inc., Westborough, Mass. 01581). Levonordefrin is a sympathomimetic amine with a pharmacological profile similar to that of epinephrine, but with a lower potency. The local anesthetic reversal agent (LARA) was prepared as follows: A standard vial containing 5 mg of lyophilized phentolamine-mesylate for injection, USP (Bedford Laboratories, Bedford, Ohio 44146) was reconstituted with 1 ml of physiological saline using a sterile, disposable 3 ml syringe and a sterile disposable hypodermic needle. After dissolution of the lyophilized powder, 0.5 ml of the phentolamine-mesylate solution was withdrawn and injected into a 50 ml vial of physiological saline for injection (USP) by means of a sterile disposable 3 ml syringe and a sterile disposable hypodermic needle. The resulting LARA thus consisted of 0.05 mg/ml phentolamine-mesylate in physiological saline.
Methods
Three healthy, male human subjects, age 34-50, volunteered to have local anesthetic injected in the mouth bilaterally under the lip in an easily repeatable location. The exact time of each injection was recorded. The position chosen was above (apical) the prominence of the root of the upper cuspid teeth. This is a common site selected to numb the cuspids, lateral incisors and upper lip. The volume of the local anesthetic injected was 1.7+0.1 ml on each side of the mouth. Twenty minutes after the local anesthetic was injected, each subject was re-injected with 1.6 ml of LARA on one side and 1.6 ml of physiological saline on the opposite side. A different size needle was used for the anesthetic and LARA or saline. A longer needle (1¼″) was used for the local anesthetic resulting in more solution being deposited around the infra-orbital nerves. LARA or saline were injected with a shorter needle (½″) resulting in less LARA coming into contact with the anesthetic agent around the infra-orbital nerves. After all subjects received anesthetic agent followed by LARA or saline, the subjects were asked to test the intensity of numbness on both sides at the following sites in the mouth and face: teeth, nose, upper lip and gingiva. Numbness of the teeth was tested by biting or grinding. Lip numbness was tested with the touch of the finger or tongue, and nose numbness was tested with the touch of the finger. Gingiva numbness was tested with the blunt end of a wooden cotton swab.
Blinding
Two of the subjects (E and M) were blinded with respect to the side of the mouth where LARA or saline vehicle were injected, i.e. the subjects were not told by the PI which side received LARA and which side received saline vehicle. The third subject (H) was the PI of the study who injected himself. As a consequence, subject H was not blinded with respect to the side at which LARA or saline were injected.
RESULTS
In all three subjects there was a dramatic acceleration of local anesthesia reversal on the side that had been injected with LARA compared to the side that had been injected with saline. No side-effects of any kind were noted in any of the three subjects. In general, feeling to the teeth returned first. Table I shows the times at which numbness disappeared and sensations re-appeared in the three subjects at the various sites on both sides of the mouth and face. In the early stages of recovery the subjects reported that it was somewhat difficult to determine which side of the lip was recovering first. In the later stages of recovery, however, the differences between the two sides of the lip were profound and dramatic. In the other parts of the mouth and face, lateral differences were reported to be pronounced even in the very early stages of recovery. The difficulty to sense lateral differences in the lips between the two sides early in the recovery process is thought to be due to the following fact: The labial branches of the infra-orbital nerve decussate at the midline, resulting in a crossover of innervation (and resulting sensation) at the midline of the upper lip.
TABLE 1
Subject E - LARA on right hand side (RHS), Vehicle on LHS
Recovery Time
Recovery Time LHS
Site of anesthesia
RHS (Minutes)
(Minutes)
Teeth 80% Recovered
21
85
Teeth Fully Recovered
28
101
Nose
30
143
Lip
41
83
Gingiva
46
141
Subject M - LARA on LHS, Vehicle on RHS
Recovery Time LHS
Recovery Time RHS
Site of anesthesia
(Minutes)
(Minutes)
Teeth
32
121
Nose
40
163
Gingiva
45
102
Lip
36
178
All Sensation
58
229
Subject H - LARA on RHS, Vehicle on LHS
Recovery Time
Recovery Time LHS
Site of anesthesia
RHS (Minutes)
(Minutes)
Teeth 80% Recovered
19
201
Teeth 100% Recovered
27
218
Gingiva
42
137
Lip
37
226
Nose
25
140
All Sensation
58
263
CONCLUSION
LARA had a profoundly faster effect on removing the numbness associated with local anesthesia than using physiological saline. The total amount of phentolamine-mesylate contained in the administered LARA solution was 0.08 mg (1.6 ml of a 0.05 mg/ml solution). This total dose of phentolamine-mesylate is approximately 62 times lower than the 5 mg dose approved by the FDA for systemic treatment of hypertension in pheochromocytoma patients (1 ml of a 5 mg/ml solution) and which can cause severe episodes of hypotension in normal patients. At the extremely low efficacious doses found to be effective in the present study, any systemic side effects, such as those that can occur with the FDA-approved high dose, are likely to be absent. Indeed, in the present study, no side-effects of any kind were noted during or after administration of 0.05 mg/ml phentolamine-mesylate.
Having now fully described this invention, it will be understood by those of ordinary skill in the art that the same can be performed within a wide and equivalent range of conditions, formulations and other parameters without affecting the scope of the invention or any embodiment thereof all patents, patent applications and publications cited herein are fully incorporated by reference herein in their entirety.
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Methods of reversing local anesthesia are disclosed. The methods comprise administering a local anesthetic and alpha adrenergic receptor agonist to induce local anesthesia followed by reversing anesthesia with a low dose of an alpha adrenergic receptor antagonist. Also disclosed are kits comprising a local anesthetic, an alpha adrenergic receptor agonist and a low dose of an alpha adrenergic receptor antagonist.
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BACKGROUND OF THE INVENTION
The present invention relates to kiln cars used to fire ceramic items in a furnace such as a tunnel kiln. Ceramic items are usually molded in the "green" state with sufficient structural integrity to withstand moderate handling and then fired to produce the finished ceramic item. For many applications the uniformity of the physical properties of the items fired is extremely important and in practice this means that each item should experience essentially the same thermal exposure in terms of time and temperature. Since many of the items to be fired are relatively small, it is not practical to fire each individually and kiln cars have been designed to carry batches of green items into the kiln for firing. These cars typically comprise a box into which the items are loaded and a support chassis on which the box is mounted and moved into and out of the kiln, perhaps on a fixed rail system.
The box portion of the car is typically made from ceramic plates or blocks supported in a suitable manner. The plates are usually made from a ceramic capable of withstanding the temperatures encountered in the kiln and the repeated thermal cycling involved in moving items into and out of the kiln. Where a supporting framework is used this can be in form of a frame in which the plates sit or the supports may be provided by a plurality of posts or pillars which support the plates at their corners such that up to four are supported on each post. The ceramic blocks that provide the sides and the bottom of the box are more usually made of a relatively cheap ceramic. However such ceramics may be subject to plastic deformation at the high temperatures in the kiln and eventually become so badly distorted that they have to be replaced. While such blocks are cheap relative to the framework materials, they are not inexpensive. In addition the kiln car must be taken out of service while it is being reconstructed and this necessarily involves commercial penalties. Therefore anything that prolongs the life of a kiln car while improving the uniformity of the products fired therein and the ease of handling of the items before and after firing, would be very significant from a technical as well as commercial viewpoint. The present invention meets both these objectives.
In one aspect, the present invention relates primarily to the design of the box structure in which the green items are carried which allows the box to have a prolonged useful life and facilitates loading and unloading operations.
Another aspect of the invention provides a means of loading and unloading kiln cars which ensures minimum handling damage, uniform thermal exposure to the items fired and an enhanced durability of the car.
DESCRIPTION OF THE INVENTION
The present invention provides a kiln car comprising a support chassis and a box wherein the box comprises removable side members and a base comprising a frame structure supporting a plurality of ceramic plates, said base being adapted to be separable into at least two sections which are rotatable with respect to one another so as to provide at least one V-shaped channel, and further rotatable to restore the box configuration with the difference that the plates comprising the base have been inverted from their pre-rotation configuration.
The rotation of the frame sections permits the fired materials to be slid onto a conveyor device carrying them away from the car without waiting for the temperature to fall to a point at which the car can be unloaded using conventional techniques. The further rotation to invert the plates has a very beneficial effect. When the base plates pass into the furnace laden with the green items to be fired, they are raised to a temperature at which some degree of plastic flow may be anticipated, particularly if the load is heavy. This can lead to a plate that is so bowed by successive passages through the kiln that the base loses its structural integrity. By inverting the plates before the next load is charged in to the car, the direction of distortion upon firing is reversed such that the previous distortion is, in effect, corrected. As a result the plates can be expected to have a much longer useful life than plates that always present the same surface to the green items to be fired.
Additionally any residue left in the box after firing drops out when the plates are inverted such that the box is less likely to be a source of contamination to subsequent loads charged in to the box.
The base is preferably made up of rectangular plates that lie in contiguous relationship to make up a rectangular base for the box but without a separate confining structure. Other plate shapes and configurations are possible of course without departing from the idea that the plates form a base without significant gaps between them but with no confining structure while the box is in contact with the chassis. In the preferred structure the plates are supported on a plurality of pillars, each plate being supported on a post at each of its four corners, (for a rectangular plate). When the box is removed from the chassis, it is supported upon lifters that pass beneath the base from two opposed sides of the box and hold the plates in place as the box is moved. These lifters are preferably provided with retainer devices that can be activated when the base is separated into at least two parts to allow the fired items to slide through a channel between the separated parts and on to a collector device such as a conveyor. These retainer devices can take the form of retractable projections that line the edges of the parts into which the base is separated. When the parts are tilted these hold the plates together and prevent them separating. They also help to maintain the parts together while the parts are inverted prior to replacing the base on the support posts when the box is re-formed. The retainer devices are preferably adapted to allow the base to separate lengthwise into two equal halves with a channel between when the parts are tilted inwardly.
Where a frame is used it is in general preferred that the frame separates in to equal pieces dividing the base lengthwise in to two equal halves separated by a channel through which fired items supported on the base can be allowed to fall on to a collecting surface such as conveyor. Obviously however it would be possible to provide for a plurality of such removal mechanisms providing a plurality of discharge channels located between opposed pairs of tilted base plates separated at the bottom by a suitable distance to provide the discharge channels.
It is also a preferred feature of this invention that, when the box is separated from the support chassis to be moved under a loading point of a device such as a conveyor, it is supported on sensing devices such as load cells which monitor the weight of the green items in the box at all points. With such an arrangement the box can be moved responsive to the sensors to ensure that the box is uniformly loaded before it is passed into the kiln.
The separability of the box also assists in the discharge operation. In this the box is removed from the support chassis and located directly above a receiving surface, such as a conveyor belt. When the plates are separated the fired items fall a relatively short distance through discharge channels between the separated plates and on to the conveying surface without need for external handling.
As will be appreciated from the above, the entire loading and unloading process can be automated with the result that process variations can be reduced and handling damage minimized.
DRAWINGS
The operation of a preferred embodiment of the invention is illustrated in the drawings in which FIGS. 1-5 are schematic side elevations showing the various stages in loading and unloading the kiln car. FIG. 6 is a top view of the box and FIGS. 7 and 8 are respectively side and end views of the kiln car.
DESCRIPTION OF PREFERRED EMBODIMENTS
The invention is now more fully described with reference to the Drawings.
FIG. 1 shows a kiln car comprising a box, 1, supported on a chassis, 2, moved into its initial loading point position below a feed conveyor, 3. The box comprises a base, 4, and side plates, 5, held in place by end traps, 6. The box is supported on pillars, 7, which form part of the chassis which in turn is able to move along rails, 8, on wheels, 9. The conveyor, 3, bears green product, 10, for loading into the box.
FIG. 2 shows the box of the kiln car removed from the chassis and raised in the direction of the arrows to a position to receive green items ready for firing from the conveyor. The box is supported on a series of arms, (not shown), bearing load cells which register the weight of items loaded at each point in the box. The arms pass under the base from either side of the box and provide individual support for all the plates during the movement to and from the conveyor. The arms may also be provided with retaining devices that line the sides of the base to provide further assistance in maintaining structural integrity of the box during the movement.
FIG. 3 shows green items being loaded into the box which is moved as filling proceeds in the direction of the arrows, and optionally also at right angles to this direction, in response to readings from the load cells to ensure a uniform loading of the box.
FIG. 4 shows the filled box replaced back on the chassis of the car ready for entry into a furnace, not shown, for firing.
FIG. 5 shows the kiln car after the firing with the box removed from the chassis with the base supported on a second pair of support arms passing under the base similar to the ones used during the loading phase. The box is placed in position over an unloading conveyor, 12. The box has also been dismantled by removal of the side plates, (not shown), and the end traps, 6. The base has been separated into two sections with retaining means, (not shown), retaining the halves of the base in position as they tilt inwardly so as to deposit the fired items on to the unloading conveyor through a discharge channel between the halves.
FIG. 6 shows a top view which clearly demonstrates the construction of the base of the box which is rectangular and is made up of 24 similar rectangular plates, 13. The base is bounded on the long sides by side plates, 5, held in place by end traps, 6. The base is supported on a series of posts, 7, while on the chassis.
After unloading of the fired items is completed, the two halves of the base plate are flipped over and replaced on the pillars of the chassis so that the face on which the fired items were carried is now the underside of the box. The side plates are then installed and locked in place by the end blocks thus reconstituting the kiln car ready for re-loading with items to be fired.
The box has been shown with the base plates separating into two equal parts lengthwise down the car. This is not essential since the objective is simply to unload the items in a uniform way with minimal mutual abrasion. This could also be achieved by splitting the base to provide three discharge gaps across the width of the box between first and second, third and fourth, and fifth and sixth rows of plates respectively.
In addition there are many other equivalent structural arrangements by which the objectives achieved by the structure described above could be attained. For example the base plates could be flipped over individually and manually or in the form of the complete base. The base could be arranged to be made of interlocking plates that, once locked in position, provide a base with inherent structural stability such that a system of support posts or a support frame is not needed. The base could also be made from more or fewer plates providing it can be separated into at least two portions separated by at least one discharge channel. It is intended that all such structures be embraced within the scope of this invention.
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An improved kiln car comprises a car with a load box with a base that can be separated into parts that can be reconfigured to form a discharge and then rotated to reform the base but with the load-bearing side on the underside so as to present a clean side to the next load of green items to be fired and to counter the cumulative effects of distortion as the load bearing base makes repeated passes through the kiln.
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OBJECT OF THE INVENTION
[0001] The present invention is a flow deflector suitable for a heat exchanger of the type consisting of at least one core made up of tubes forming a bundle arranged inside a shell and at least one baffle. The deflector according to the invention is an easily manufactured part independent from the construction of the bundle of tubes and of the baffle which allows modifying the coolant fluid or liquid flow path with greater freedom than that achieved by combining internal openings in the baffle or baffles.
[0002] Another object of this invention is the heat exchanger obtained using the deflector for optimising coolant liquid flow path.
[0003] The application of the invention in heat exchangers for EGR (Exhaust Gas Recirculation) systems is of special interest.
BACKGROUND OF THE INVENTION
[0004] The configuration of heat exchangers for EGR systems usually consists of a bundle of tubes through which the recirculated gas passes and of a shell housing said bundle of tubes. A coolant fluid circulates between the bundle of tubes and the shell such that the gas circulating through the tubes transfers heat to the coolant liquid.
[0005] In most cases the entry of the coolant liquid occurs at one point of the shell corresponding to an end of the bundle; and the exit at another point of the shell located at the opposite end of the bundle. The entry through a point establishes regions of the volume occupied by the coolant liquid which are stagnation regions. Since the speed is zero or very small in stagnation regions, convection is very low and therefore heat dissipation to other areas does not occur. As a result, the temperature is higher in these areas and worse still the materials which are in contact with these stagnation regions suffer greater thermal stresses. As a result of these high stresses in localised sites of the device, the service life of the materials is unfailingly reduced since they withstand a lower number of thermal fatigue cycles.
[0006] A decrease in thermal stress level implies an increase in the number of thermal fatigue cycles withstood by the device without it malfunctioning. This increase in thermal fatigue cycles withstood by the device follows the behaviour similar to that of an exponential function. The decrease in thermal stresses and therefore in thermal fatigue, and the subsequent increase in the exchanger durability is achieved by means of a homogenous temperature distribution especially in the hotter areas.
[0007] To prevent the existence of stagnation regions, flow deflection means are incorporated, for example, for moving the coolant liquid in a zigzag manner and increasing its speed and thus improving heat convection.
[0008] This flow deflection is achieved by means of the shape of the inner openings of the baffles responsible for securing the tubes of the bundle of tubes assuring a specific separation between said tubes. The more common configuration of these baffles is that of a perimetric ring-shaped die-cut plate according to the configuration of the perimeter of the bundle of tubes; and, having elongations towards the inside of the comb-shaped perimetric ring. These comb-shaped elongations are intended for being housed between the tubes of the bundle and prevent the passage of the coolant liquid through them.
[0009] If the elongations are short the opening left by these elongations inside the bundle are larger. The flow passing through these baffles is forced to follow the path imposed by the position and size of the openings by combining several baffles with different internal openings, the openings defining the ends of these elongations. For example, placement on alternate sides of the internal openings will give rise to a zigzag path.
[0010] Even though it reduces the existence of stagnation regions this solution has significant limitations as detailed below.
[0011] Incorporating the baffles to the bundle of tubes allows assuring the distances between tubes. Manufacturing is carried out by die-cutting sheet metal which is welded to this bundle. If the comb-shaped elongations of the baffles are excessively styled the manufacturing complexity increases given that dimensional stability and the tolerances demanded by mass production are more difficult to achieve.
[0012] Increasing the internal distance between tubes allowing wider and therefore stiffer and more stable elongations is a possible option when faced with this problem. This solution has the drawback of reducing the amount of tubes which can be bundled into one and the same volume and therefore the efficiency is severely reduced.
[0013] Reducing the length of the comb-shaped elongations is also possible. The drawback of this alternative is that the distribution of coolants is worse since the flow deflection and interaction are lower.
[0014] Other additional limitations of the baffles is the need of being arranged essentially perpendicular to the tubes of the bundle of tubes therefore the deflection is not always optimum and the pressure losses are higher than if oblique flow deflections could occur.
[0015] In order to solve these problems the present invention uses a part intended for being secured, preferably by clipping, in an already existing baffle the configuration of which is not limited by manufacturing demands, by geometry limitations of a part obtained by die-cutting sheet metal, and by limitations of baffle welding.
DESCRIPTION OF THE INVENTION
[0016] The present invention solves the problems identified above by using a part which can be manufactured in plastic, resin or other materials, intended for being installed, preferably by clipping, on a baffle. In this case the baffle can be of very simple design since it is no longer required to be responsible for coolant fluid or liquid flow deflection. The part according to the invention is a flow deflector suitable for a heat exchanger of the type consisting of at least one core made up of tubes forming a bundle arranged inside a shell and at least one baffle, such that said deflector comprises:
a main body extending along an X-X direction, This main body extends on the edge of said baffle when the deflector is operatively installed on the baffle. Given that the baffle is arranged perpendicular to the tubes of the bundle, the direction identified as X-X will correspond both to the transverse direction and to the direction in which the mentioned main body extends.
[0019] The X-X direction is a geometric reference for the remaining components of the deflector of the invention.
a plurality of at least three fixing elongations protruding transversely with respect to the X-X direction of the main body defining a main plane P containing the X-X direction, wherein such fixing elongations are such that:
they are formed by two groups, a first group of fixing elongations and a second group of fixing elongations such that the first group of fixing elongations is distributed along the X-X direction and located on one side of the main plane P; and wherein the second group of fixing elongations is distributed along the X-X direction in positions different from the positions of the elongations of the first group of fixing elongations and located on the opposite side of the main plane P, each of the elongations is arranged at least in a sector away from the main plane defining a housing such that the set of housings of the elongations is suitable for housing a sector of baffle of the heat exchanger for fixing the flow deflector,
[0023] Once the X-X axis has been defined, the position and orientation of the plurality of fixing elongations also defines the main plane P containing the X-X direction.
[0024] When the deflector is placed on the baffle, the fixing elongations are responsible for attaching the deflector to the bundle of tubes. The plane P coincides with the main plane of the baffle in this one and the same operating position of the deflector on the baffle. The condition of distributing fixing elongations on both sides of plane P results in the operating position with a distribution of such elongations on both sides of the baffle.
[0025] The relative movement between the deflector and the bundle of tubes in the direction perpendicular to the bundle is prevented by resting the main body on the baffle. The exit direction is limited by the existence of the shell or, as will be seen in the embodiments, by particular ways of making these fixing elongations which incorporate staggerings to secure the clipping.
[0026] The distribution on both sides of the main plane prevents the relative movement in the direction coinciding with the direction of the tubes of the bundle.
[0027] Lastly, movement parallel to the X-X direction is prevented because the fixing elongations are inserted between the tubes of the bundle in operating mode. Nevertheless, according to the embodiments which will be described below, some of these fixing elongations, preferably the end fixing elongations can have reinforcements limiting movements in this direction to the greatest extent possible.
[0028] The way in which the elongations are distributed on both sides of the plane is such that they leave a spacing to allow housing the baffle. In a view of the part according to the X-X direction, this spacing is shown in projection in an area which allows accommodating the section of the baffle on which the deflector is fixed by means of the fixing elongations.
deflecting extensions suitable for being located in the spaces located between the tubes of the core made up of tubes of the heat exchanger suitable for modifying the coolant flow path.
[0030] Once the deflector is fixed on the baffle, the part of the deflector which intervenes by modifying the coolant fluid flow path is the deflecting extensions. The position thereof depends on the particular embodiment. Two particular examples will be shown below, although there can be more; a first example in which the deflecting extensions are located at the end of the fixing elongations giving continuity to such elongations; and a second example in which these deflecting extensions are located on one side of the main plane P linked to the main body by means of a resistant bridge. This second embodiment gives no reason for flow deflection to occur in the position of the baffle. Likewise, these deflecting extensions can adopt degrees of inclination or curvature which would not be possible, or would be very complicated, to impose on one part of the baffle. These extensions, given that they do not have to be attached to the tubes of the bundle, can cover the entire width defined by the gap between the tubes producing total flow deflection; or they can partially cover the width for example for allowing the passage of coolant liquid flow and preventing stagnation regions therebehind.
DESCRIPTION OF THE DRAWINGS
[0031] These and other features and advantages of the invention will be seen more clearly from the following detailed description of a preferred embodiment provided only by way of illustrative and non-limiting example in reference to the attached drawings.
[0032] FIG. 1 shows an embodiment according to the state of the art of a heat exchanger for cooling EGR gases by means of a coolant liquid. A zigzag coolant liquid flow is imposed by means of baffles as shown by the line with arrows.
[0033] FIG. 2 shows a baffle according to an example of the state of the art with comb-shaped elongations which do not need to have the same length. The length of the ends of these elongations defines the size of the opening for coolant liquid passage.
[0034] FIGS. 3 a and 3 b show a bundle of tubes of a heat exchanger from which the outer shell has been removed. FIG. 3 a shows a deflector according to a first embodiment before being fixed to a baffle of the bundle of tubes. FIG. 3 b shows the same part once inserted and in an operating position.
[0035] FIGS. 4 a , 4 b , 4 c and 4 d show an elevational view, profile view and two different perspective views of the same deflecting part according to the first embodiment.
[0036] FIG. 5 shows a side perspective view of the deflector according to a second embodiment orientated towards the bundle of tubes and the baffle to allow observing the most relevant attachment means and elements of its structure.
[0037] FIG. 6 shows the same embodiment as in the preceding figure only that the angle of the perspective is slightly rotated to allow observing details which cannot be observed in the preceding perspective.
[0038] FIG. 7 shows a sector of the bundle of tubes of a heat exchanger with the baffle and the deflecting part according to the second embodiment before being inserted.
[0039] FIG. 8 essentially shows the same as in the preceding figure only that the deflecting part is shown already fixed on the baffle.
[0040] FIG. 9 shows a cross-section with respect to the X-X direction according to a plane passing between two tubes of the bundle of tubes of the exchanger to allow observing the position of the fixing elements and of the deflecting extensions in their operating position.
DETAILED DESCRIPTION OF THE INVENTION
[0041] FIG. 1 shows a heat exchanger according to the state of the art formed by a core ( 2 ) and a shell ( 3 ) where coolant liquid flow is directed by means of baffles ( 2 . 2 ) for the purpose of increasing heat convection and therefore exchanger efficiency. The existence of stagnation regions in the coolant liquid flow means that the liquid which is in said stagnation region raises its temperature reaching boiling temperature.
[0042] Such effects cause material fatigue and breakage drastically reducing the service life of the device.
[0043] The baffles ( 2 . 2 ) are resistant elements which must be welded to the bundle ( 2 ) of tubes ( 2 . 1 ). The manufacturing and welding requirements do not have to be compatible with the deflection surface requirements and therefore do not allow defining an optimum flow configuration.
[0044] FIG. 2 shows a baffle ( 2 . 2 ) incorporating comb-shaped elongations intended for being housed between the tubes ( 2 . 1 ) of the bundle ( 2 ) covering the space defining the separation between the tubes. The ends of the comb-shaped elongations are the edges of the internal window through which the passage of the coolant liquid is allowed. The passage and path of the coolant liquid can be modified by alternating the areas and positions of these windows but it has the drawbacks already mentioned in the state of the art.
[0045] The present invention uses a part, the deflector ( 1 ), intended for being incorporated in a baffle ( 2 . 2 ) where this baffle ( 2 . 2 ) is very simple to manufacture since it does not require thin and long elongations for modifying inner coolant liquid flow.
[0046] A first embodiment of the invention is shown in detail in FIGS. 4 a , 4 b , 4 c and 4 d . FIGS. 4 a and 4 b are the elevational, profile view of this first example whereas FIGS. 4 c and 4 d are two perspective views which allow observing the same part ( 1 ) from almost opposite positions for offering visual access to all the details.
[0047] Before describing this embodiment in detail, the deflector ( 1 ) according to this first embodiment is seen before and after being inserted in its operating position by means of FIGS. 3 a and 3 b . In FIG. 3 a the deflector ( 1 ) is located on the baffle ( 2 . 2 ) such that in this view it is possible to see the protruding edge of the baffle ( 2 . 2 ) on which the deflector ( 1 ) will be located. In this embodiment, the baffle ( 2 . 2 ) has a configuration with short internal elongations such that it does not limit the flow of coolant liquid through it.
[0048] Using FIGS. 4 a - 4 d it is seen that the deflector ( 1 ) comprises a main body ( 1 . 1 ) extending along the X-X direction. The main body ( 1 . 1 ) is intended to rest on the baffle ( 2 . 2 ) and the elongations ( 1 . 2 , 1 . 3 ) which allow fixing on the baffle ( 2 . 2 ) protrude from the main body. FIG. 4 b shows the main plane P, which in this embodiment coincides with the plane of symmetry, leaving a group of fixing elongations ( 1 . 2 ) on one side and the remaining fixing elongations ( 1 . 3 ) on the other side. This same view 4 b as well as the perspective view 4 d allow observing the spacing of the fixing elongations ( 1 . 2 , 1 . 3 ) with respect to plane P and therefore the separation between both groups of elongations. Said separation gives rise to a housing (H) for the sector of baffle ( 2 . 2 ) resulting in a fixing mode between both elements ( 1 , 2 . 2 ).
[0049] In the particular case of this embodiment, each of the fixing elongations ( 1 . 2 , 1 . 3 ) has a deflecting extension ( 1 . 2 . 2 , 1 . 3 . 2 ) configured as a continuation of the fixing elongation ( 1 . 2 , 1 . 3 ). In the attachment between the fixing elongation ( 1 . 2 , 1 . 3 ) and the deflecting extension ( 1 . 2 . 2 , 1 . 3 . 2 ) there is a staggering arranged on the inner side orientated towards the main plane P. This staggering is intended for resting on the end of the elongations of the baffle ( 2 . 2 ) assuring their retention and preventing them from coming out.
[0050] In other cases, instead of using this staggering it is possible for the main body ( 1 . 1 ) to rest on the internal face of the shell ( 3 ) of the heat exchanger.
[0051] The ends of the deflecting extensions ( 1 . 2 . 2 , 1 . 3 . 2 ) of this embodiment are bevelled on the inner side orientated towards the main plane P. This beveling allows the insertion on the baffle ( 2 . 2 ) during assembly facilitating the opening by means of bending the set formed by the deflecting extension ( 1 . 2 . 2 , 1 . 3 . 2 ) and the fixing elongation ( 1 . 2 , 1 . 3 ). The insertion is completed when the sector of baffle ( 2 . 2 ) which is housed in the housing (H) overcomes the staggerings ( 1 . 2 . 1 , 1 . 3 . 1 ) allowing the shape recovery of the set of fixing elongations ( 1 . 2 , 1 . 3 ) together with the deflecting extensions ( 1 . 2 . 2 , 1 . 3 . 2 ). In this embodiment, a material with elastic behaviour in the range of deformations imposed by the thickness of the baffle ( 2 . 2 ) and the different dimensions of the deflector ( 1 ) intervening in the insertion has been selected for allowing an easy shape recovery.
[0052] A second embodiment is shown in detail in FIGS. 5 and 6 . According to this embodiment the main body ( 1 ) extends according to the X-X direction and comprises a channel ( 1 . 6 ) which also extends in the X-X direction intended for housing the outer edge of the baffle ( 2 . 2 ) when the deflector ( 1 ) is installed on the baffle ( 2 . 2 ).
[0053] FIG. 5 shows a perspective view of the main plane P passing in the X-X direction and leaving the fixing elongations ( 1 . 2 , 1 . 3 ) on both sides. In this particular case the fixing elongations ( 1 . 2 , 1 . 3 ) are shown in groups of three, and in each group of three, two fixing elongations ( 1 . 3 ) are on one side and the third fixing elongation ( 1 . 2 ) is on the opposite side of the main plane P. This third fixing elongation ( 1 . 2 ) is arranged between the other two fixing elongations ( 1 . 3 ) following the X-X direction. Only three fixing elongations ( 1 . 2 , 1 . 3 ) would thus be sufficient for assuring a fixing preventing movements in directions perpendicular to the X-X direction and even rotational movements.
[0054] In this embodiment the beveling which facilitates the insertion of the deflector ( 1 ) in the baffle ( 2 . 2 ) is in the fixing elongations ( 1 . 2 , 1 . 3 ).
[0055] A resistant bridge ( 1 . 4 ) at the end of which a plurality of deflecting extensions ( 1 . 5 ) starts extends from the main body ( 1 . 1 ). In this embodiment there are as many deflecting extensions ( 1 . 5 ) as there are cavities between tubes ( 2 . 1 ) such that each deflecting extension ( 1 . 5 ) is intended for entering a space between tubes ( 2 . 1 ). Additionally, there are two end side extensions with reinforcement ( 1 . 5 . 1 ) suitable for externally supporting the bundle ( 2 ) of tubes ( 2 . 1 ) and also covering the space between the bundle ( 2 ) of tubes ( 2 . 1 ) and the shell ( 3 ). The space between tubes ( 2 . 1 ) is narrower than the space between the bundle ( 2 ) of tubes ( 2 . 1 ) and the shell ( 3 ). The lower flow resistance in this second space means that the entire flow tends to circulate outside the bundle of tubes ( 2 . 1 ). The presence of reinforcement ( 1 . 5 . 1 ) covering the space between the bundle ( 2 ) of tubes ( 2 . 1 ) and the shell ( 3 ) has the effect of forcing the flow to circulate between the tubes ( 2 . 1 ) increasing the cooling efficiency.
[0056] With respect to the deflecting extensions ( 1 . 5 ), in this embodiment, they have a width slightly less than the space between tubes ( 2 . 1 ) giving rise to a clearance. Although the deflecting extensions ( 1 . 5 ) divert the flow reaching them, the existence of a clearance allows a small part of the flow to pass between the deflecting extension ( 1 . 5 ) and the tube ( 2 . 1 ) preventing stagnation regions which would give rise to points which could easily reach boiling temperature behind the deflecting extension ( 1 . 5 ).
[0057] In this embodiment, the deflecting extensions ( 1 . 5 ) elongate by way of ribs until reaching the main body ( 1 . 1 ).
[0058] FIG. 8 shows the bundle ( 2 ) of tubes ( 2 . 1 ) after having removed the shell ( 3 ) with the flow deflector ( 1 ) before being inserted on the baffle ( 2 . 2 ). The fixing elongations ( 1 . 2 , 1 . 3 ) enter the spaces between tubes ( 2 . 1 ) being located on both sides of the baffle ( 2 . 2 ) by means of the downwards movement thereof (moving downward according to the orientation shown in the figure). In turn, the deflecting extensions also enter the spaces between the tubes ( 2 . 1 ) reaching the final position which is shown in FIG. 8 . This figure shows two baffles ( 2 . 2 ); nevertheless, flow deflection does not occur in the position of the baffles ( 2 . 2 ) but in the position where the deflecting extensions ( 1 . 5 ) are located which, as a result of the resistant bridge ( 1 . 4 ), are away from the baffle ( 2 . 2 ). The design requirements for positioning the baffles ( 2 . 2 ) based on resistant criteria thus do not impose the position of the deflecting extensions ( 1 . 5 ) this second position depending on flow criteria to be imposed on the coolant liquid so that the heat exchange is carried out efficiently and without stagnation regions.
[0059] FIG. 9 shows a section of the heat exchanger according to a plane which is orientated in the direction of the tubes ( 2 . 1 ) of the bundle ( 2 ). The tubes ( 2 . 1 ) are essentially planar. This section allows observing how the deflecting extensions ( 1 . 5 ) reach approximately the width of one of the two tubes ( 2 . 1 ) giving rise to the total height of the bundle ( 2 ) of tubes ( 2 . 1 ). The flow will be diverted so that it will be redirected to the lower tubes ( 2 . 1 ) (also following the orientation shown in the drawing). In this embodiment, the deflecting surfaces are inclined so that the diverted flow has an axial component according to the main axis of the bundle ( 2 ) of tubes ( 2 . 1 ). Nevertheless, these extensions can adopt other more complex configurations such as curves imposing a specific configuration to the stream lines.
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The present invention is a flow deflector suitable for a heat exchanger of the type consisting of at least one core made up of tubes forming a bundle arranged inside a shell and at least one baffle. The deflector according to the invention is an easily manufactured part independent from the construction of the bundle of tubes and of the baffle which allows modifying the coolant fluid or liquid flow path with greater freedom than that achieved by combining internal openings in the baffle or baffles. Another object of this invention is the heat exchanger obtained using the deflector for optimising coolant liquid flow path. The application of the invention in heat exchangers for EGR (Exhaust Gas Recirculation) systems is of special interest.
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This application is a division of application Ser. No. 11/012,218, filed Dec. 16, 2004, now pending, based on Japanese Patent Application No. 2003-419635, filed Dec. 17, 2003, by Hidehiko FUJIWARA and Naoki MORI, which is incorporated herein by reference in their entirety. This application claims only subject matter disclosed in the parent application and therefore presents no new matter.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a communication transfer apparatus and a communication transfer method for transferring communications. More particularly, the present invention relates to a communication transfer apparatus and a communication transfer method for switching a terminal communicating with another terminal by way of the global IP (internet protocol) network to some other terminal belonging to the local IP network to which the first terminal belongs.
2. Related Background Art
As the development of Internet-related technologies, IP telephony that utilizes the Internet is becoming very popular. With IP telephony, a voice communication can proceed by means of RTP (real-time transport protocol) or some other protocol once a communication line is established by signaling by means of SIP (session initiation protocol), H.323 protocol or some other protocol.
Technological documents that describe the conventional art relating to the present invention include JP 11-205475 A, JP 2000-286882 A and JP 2003-46665 A.
However, the IP telephony that is becoming popular has a prerequisite that a single IP telephone terminal is connected to a single router that is installed in an office or a home.
In other words, when there is an IP telephone call, the router establishes a corresponding relationship between the combination of the global IP address and the global port number and the combination of the local IP address and the local port number of the called terminal by means of the technique of NAT (network address translation) or IP masquerade and the corresponding relationship continues as long as the IP telephone communication proceeds.
Therefore, if more than one IP telephone terminals are connected to the router, it may be conceivable to use either of the following two techniques in order to transfer the IP telephone communication of an IP telephone terminal to another IP telephone terminal.
The first one is to request the global network or the other end of the line to change the global port number that corresponds to the local IP address and the local port number of the IP telephone terminal before the transfer to the global port number that corresponds to the local IP address and the local port number of the IP telephone terminal of the destination of transfer.
However, any existing Internet service provider cannot accommodate such a request and any existing router cannot accommodate such a request either.
The second conceivable technique is to terminate the IP packets to be used with the other end of the line for IP telephone communication and install a particular device for IP telephone communications in the local IP network.
However, while an IP telephone communication can be realized between two terminals on a peer to peer basis, installing such a device for the purpose of termination and redistribution will again raise the cost that has been reduced once.
The above-identified problem arises not only in IP telephone communications but also in visual phone communications, television games and communications using messengers.
SUMMARY OF THE INVENTION
In view of the above described circumstances, it is therefore an object of the present invention to provide a communication transfer apparatus and a communication transfer method that eliminate the necessity of requesting the global IP network (Internet) to switch the port number and allow to transfer communications at low cost.
According to a first aspect of the present invention, there is provided a communication transfer apparatus comprising rewriting means for rewriting a local internet protocol address of an origin terminal of transfer described in a record relating to the transfer out of records of a masquerade table which is utilized for an internet protocol masquerade into a local internet protocol address of a destination terminal of the transfer, while maintaining a global port number of the record.
The communication transfer apparatus according to the first aspect may further comprise: local internet protocol address of origin of transfer detecting means for detecting a local internet protocol address of an origin of the transfer assigned to the origin terminal of the transfer; and local port number of origin of transfer detecting means for detecting a local port number of the origin of the transfer utilized by the origin terminal of the transfer, wherein said rewriting means identifies the record relating to the transfer by the local internet protocol address of the origin of the transfer detected by said local internet protocol address of origin of transfer detecting means and the local port number of the origin of the transfer detected by said local port number of origin of transfer detecting means.
The communication transfer apparatus according to the first aspect may further comprise: an extension number versus local internet protocol address correspondence table storing a relationship between an extension number assigned to each terminal and a local internet protocol address assigned to the terminal; and extension number of origin of transfer detecting means for detecting the extension number of the origin of the transfer assigned to the origin terminal of the transfer, wherein said local internet protocol address of origin of transfer detecting means detects a local internet protocol address corresponding to the extension number of the origin of the transfer detected by said extension number of origin of transfer detecting means from said extension number versus local internet protocol address correspondence table as the local internet protocol address of the origin of the transfer.
The communication transfer apparatus according to the first aspect may further comprise: local internet protocol address of destination of transfer detecting means for detecting a local internet protocol address of a destination of transfer assigned to the destination terminal of the transfer, wherein said rewriting means rewrites the local internet protocol address of the origin terminal of the transfer described in the record relating to the transfer into a local internet protocol address of the destination of transfer detected by said local internet protocol address of destination of transfer detecting means.
The communication transfer apparatus according to the first aspect may further comprise: an extension number versus local internet protocol address correspondence table storing a relationship between an extension number assigned to each terminal and a local internet protocol address assigned to the terminal; and extension number of destination of transfer detecting means for detecting the extension number of the destination of the transfer assigned to the destination terminal of the transfer, wherein said local internet protocol address of destination of transfer detecting means detects a local internet protocol address corresponding to the extension number of the destination of transfer detected by said extension number of destination of transfer detecting means from said extension number versus local internet protocol address correspondence table as the local internet protocol address of the destination of transfer.
In the communication transfer apparatus according to the first aspect, said rewriting means may realize the rewrite by erasing the record relating to the transfer and adding a record describing a global port number identical with the global port number described in the erased record and the local internet protocol address of the destination terminal of the transfer to said masquerade table.
The communication transfer apparatus according to the first aspect may further comprise: local internet protocol address of origin of transfer detecting means for detecting a local internet protocol address of an origin of the transfer assigned to the origin terminal of the transfer; local port number of origin of transfer detecting means for detecting a local port number of the origin of the transfer utilized by the origin terminal of the transfer; a replica of said masquerade table; and retrieving means for retrieving a global port number corresponding to the local internet protocol address of the origin of the transfer detected by said local internet protocol address of origin of transfer detecting means and the local port number detected by said local port number of origin of transfer detecting means from the replica, wherein said rewriting means identifies the record relating to the transfer by the global port number retrieved by said retrieving mans and write the global port number detected by said retrieving means into the added record.
According to a second aspect of the present invention, there is provided a communication transfer apparatus comprising: presence information storing means for storing information on presence or absence of a user at each terminal and information on priorities of terminals for each user; called terminal detecting means for detecting a called terminal; presence determining means for determining presence or absence of a user at the called terminal detected by said called terminal detecting means by referring to said presence information storing means; destination of transfer identifying means for identifying a terminal having a next priority by referring to said presence information storing means if said presence determining means determines absence of a user at the called terminal detected by said called terminal detecting means; and record creating means for creating a record describing a local internet protocol address of the terminal identified by said destination of transfer identifying means as well as a global port number and local port number to be used for communication to a masquerade table utilized for an internet protocol masquerade.
According to a third aspect of the present invention, there is provided a communication transfer apparatus comprising: priority storing means for storing information on priorities of terminals for each user; called terminal detecting means for detecting a called terminal; presence determining means for determining execution or non-execution of a hooking off operation at the called terminal detected by said called terminal detecting means within a predetermined period of time; destination of transfer identifying means for identifying a terminal having a priority next to a priority of the called terminal by referring to said priority storing means if said presence determining means determines non-execution of the hooking off operation at the called terminal detected by said called terminal detecting means within the predetermined period of time; and record creating means for creating a record describing a local internet protocol address of the terminal identified by said destination of transfer identifying means as well as a global port number and local port number to be used for communication to a masquerade table utilized for an internet protocol masquerade.
Thus, according to the invention, it is no longer necessary to request the global IP network (Internet) to switch the port number so that it is possible to transfer communications at low cost.
Additionally, according to the invention, an effect similar to that of rewriting a masquerade table can be obtained by erasing a record and adding another record, referring to a replica of the masquerade table if it is not possible to acquire information therefrom for identifying the record of the masquerade table to be rewritten and if it is not possible to directly rewrite the record of the masquerade table.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a schematic block diagram of a communication system realized by means of an embodiment of the present invention, illustrating the configuration thereof;
FIG. 2 is a schematic block diagram of the own office router and the call control device of a first embodiment of the present invention, illustrating the configuration thereof;
FIG. 3 is a schematic illustration of the masquerade table of FIGS. 2 and 11 , showing the configuration thereof;
FIG. 4 is a schematic illustration of the extension number versus local IP address correspondence table of FIGS. 2 and 11 , showing the configuration thereof;
FIG. 5 is a schematic illustration of the first format of information to be stored in the presence information storage section of FIGS. 2 and 11 ;
FIG. 6 is a schematic illustration of the second format of information to be stored in the presence information storage section of FIGS. 2 and 11 ;
FIG. 7 is a flow chart of the operation of the call control device and other related components of the first embodiment of the present invention at the time of starting a communication;
FIG. 8 is a flow chart of the operation of the call control device and other related components of the first embodiment of the present invention at the time of a transfer;
FIG. 9 is a flow chart of the operation that is conducted by using the presence information of the call control device and other related components and by using the first method at the time of starting a communication of the first embodiment of the present invention;
FIG. 10 is a flow chart of the operation that is conducted by using the presence information of the call control device and other related components and by using the second method at the time of starting a communication of the first embodiment 1 of the present invention;
FIG. 11 is a schematic block diagram of the own office side router and the call control device of a second embodiment of the present invention, illustrating the configuration thereof;
FIG. 12 is a flow chart of the operation of the call control device and other related components of the second embodiment of the present invention at the time of starting a communication;
FIG. 13 is a flow chart of the operation of the call control device and other related components of the second embodiment of the present invention at the time of a transfer;
FIG. 14 is a flow chart of the operation that is conducted by using the presence information of the call control device and other related components and by using the first method at the time of starting a communication of the second embodiment 2 of the present invention; and
FIG. 15 is a flow chart of the operation that is conducted by using the presence information of the call control device and other related components and by using the second method at the time of starting a communication of the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described by referring to the accompanying drawings that illustrate the preferred embodiments of carrying out the invention.
[Embodiment 1]
FIG. 1 a schematic block diagram of a communication system realized by means of an embodiment of the present invention, illustrating the configuration thereof. An own office has an own office side router 101 , a call control device 102 and first through N-th terminals including a first terminal 103 - 1 , a second terminal 103 - 2 , . . . , an N-th terminal 103 -N. The own office side router 101 , the call control device 102 and the first terminal 103 - 1 , the second terminal 103 - 2 , . . . , the N-th terminal 103 -N are connected to a local IP network 104 . The call control device 102 is connected to the first terminal 103 - 1 , the second terminal 103 - 2 , . . . , the N-th terminal 103 -N by way of respective control lines 105 - 1 , 105 - 2 , . . . , 105 -N.
The partner office has a partner office side server 112 and a partner office side terminal 113 .
The own office side router 101 and the partner office side server 112 are connected to each other by way of a global IP network (the Internet) 111 . Therefore, the partner office side terminal 113 is adapted to communicate with any of the first terminal 103 - 1 , the second terminal 103 - 2 , . . . , the N-th terminal 103 -N by way of the partner office side server 112 , the global IP network 111 and the own office side router 101 .
As shown in FIG. 2 , the own office side router 101 is provided with a masquerade table 101 - 1 , an IP masquerade section 101 - 2 and a negotiation section 101 - 3 . The own office side router 101 additionally has functional sections (not shown) that an ordinary router is normally provided with.
As shown in FIG. 3 , the masquerade table 101 - 1 stores one or more records each describing a relationship between a combination of a global IP address and a global port number and a combination of a local IP address and a local port number. In the example of FIG. 3 , the first record describes that the combination of global IP address 10.10.20.1 and global port number 50001 corresponds to the combination of local IP address 192.168.0.11 and local port number 60001. In this embodiment, a record may be added to, modified in or erased from the masquerade table 101 - 1 appropriately whenever necessary. The global IP address may be omitted from the masquerade table 101 - 1 . An IP masquerade can be realized even if the global IP address is omitted from the masquerade table 101 - 1 , because it is possible to know which global port number corresponds to which combination of a local IP address and a local port number.
The IP masquerade section 101 - 2 conducts an IP masquerade by referring to the masquerade table 101 - 1 .
At the time of signaling, the negotiation section 101 - 3 negotiates with the partner office side server 112 . As a result of the negotiation, the partner office side server 112 determines the global port number to be utilized typically by the UDP/IP for RTP packet transmission or some other transmission and notifies the determined global port number to record adding section 102 - 5 . The determined global port number is not changed as long as the communication continues.
As shown in FIG. 2 , the call control device 102 has an extension number detecting section 102 - 1 , an extension number versus local IP address correspondence table 102 - 2 , a local IP address retrieving section 102 - 3 , a local port number storage section 102 - 4 , a record adding section 102 - 5 , a terminal interface 102 - 6 , a local IP address assigning section 102 - 7 , an origin-of-transfer-related information detecting section 102 - 8 , a record retrieving section 102 - 9 , a destination terminal designation receiving section 102 - 10 , a transfer hold receiving section 102 - 11 , a release terminal detecting section 102 - 12 , a post-transfer local IP address detecting section 102 - 13 , a recording rewriting section 102 - 14 , a record erasing section 102 - 15 , a presence information acquiring section 102 - 16 and a presence information storage section 102 - 17 .
When the partner office side terminal 113 designates the direct telephone number of a particular one of the first through N-th terminals 103 - 1 through 103 -N, the extension number detecting section 102 - 1 detects the extension number of the terminal on the basis of the direct telephone number. Then, the extension number detection section 102 - 1 requests the terminal interface 102 - 6 to ring a call-in bell of the terminal, using the extension number. When, on the other hand, the partner office side terminal 113 calls the representative telephone number, the extension number detecting section 102 - 1 requests the terminal interface 102 - 6 to ring a call-in bells of all the terminals. Then, the extension number detecting section 102 - 1 is notified of the extension number of the terminal that is hooked off first by the terminal interface 102 - 6 .
As shown in FIG. 4 , the extension number versus local IP address correspondence table 102 - 2 stores one or more records each describing a relationship between an extension number assigned to a terminal and a local IP address assigned to the terminal.
The local IP address retrieving section 102 - 3 receives an extension number from the extension number detecting section 102 - 1 and retrieves the local IP address corresponding to the received extension number from the extension number versus local IP address correspondence table 102 - 2 . The retrieved local IP address then becomes the local IP address of the terminal that is to start a communication.
The local port number storage section 102 - 4 holds the local port number that corresponds to the type of the coming communication.
At the time of signaling, the record adding section 102 - 5 receives the global IP address and the global port number to be used for the coming communication from the negotiation section 101 - 3 . Note, however, that it is not necessary for the record adding section 102 - 5 to receive the global IP address from the negotiation section 101 - 3 when the global IP address of the own office side router 101 is known or when no field is provided for global IP addresses in the masquerade table 101 - 1 . Additionally, at the time of signaling, the record adding section 102 - 5 receives the local IP address to be used for the coming communication (the local IP address of the terminal to be used for the coming communication) from the local IP address retrieving section 102 - 3 . Furthermore, at the time of signaling, the record adding section 102 - 5 receives the local port number to be used for the coming communication from the local port number storage section 102 - 4 . Then, the record adding section 102 - 5 adds a record describing the global IP address, the global port number, the local IP address and the local port number it has received to the masquerade table 101 - 1 . Note, however, that the added record describes only the global port number, the local IP address and the local port number when no field is provided for global IP addresses in the masquerade table 101 - 1 .
The record adding section 102 - 5 may determine the local port number by negotiating with the terminal with which it is going to communicate. The record adding section 102 - 5 may receive a designated local port number although the record adding section 102 - 5 has the initiative of the negotiation in hand.
The terminal interface 102 - 6 communicates with the first terminal 103 - 1 , the second terminal 103 - 2 , . . . , the N-th terminal 103 -N for the purpose of controlling the call.
The local IP address assigning section 102 - 7 receives the local IP address of the terminal that is to be newly added as extension from this terminal, adds a new extension number that is generated internally and adds a record describing the new local IP address and the new extension number to the extension number versus local IP address correspondence table 102 - 2 .
The origin-of-transfer-related information detecting section 102 - 8 detects the extension number or the local IP address of the terminal requesting transfer of communication. When the origin-of-transfer-related information detecting section 102 - 8 detects the extension number of the terminal requesting transfer of communication, the origin-of-transfer-related information detecting section 102 - 8 retrieves the local IP address corresponding to the extension number from the extension number versus local IP address correspondence table 102 - 2 . Additionally, the origin-of-transfer-related information detecting section 102 - 8 detects the type of the communication of which transfer is requested or the local port number that is used for the communication of which transfer is requested. If the origin-of-transfer-related information detecting section 102 - 8 detects the type of the communication of which transfer is requested, it retrieves the local port number corresponding to the type of the communication from the local port number storage section 102 - 4 . If, for example, the type of communication is limited to IP telephony and the local port number is fixed, it does not have to retrieve the local port number but have only to retain the local port number. The origin-of-transfer-related information detecting section 102 - 8 may alternatively inquire the local port number being used for communication to the origin terminal of the transfer.
The record retrieving section 102 - 9 receives the local IP address and the local port number of the origin of transfer from the origin-of-transfer-related information detecting section 102 - 8 and retrieves the record describing the received local IP address and local port number from the masquerade table 101 - 1 . Then, the record retrieving section 102 - 9 notifies the record rewriting section 102 - 14 of information for identifying the retrieved record (including the record number).
Two methods can be used for transfer of communication as described below. The first one is that the origin of transfer designates the destination of transfer. More specifically, the origin terminal of transfer holds the communication and notifies to the designated destination of transfer by way of extension that the origin terminal of transfer transfers the communication to the designated destination of transfer. Then, the origin terminal of transfer selects the designated destination of transfer after disconnecting the extension. The communication resumes as the designated destination of transfer release the communication that has been held. The second method is that the origin of transfer does not designate the destination of transfer. More specifically, the origin terminal of transfer holds the communication and the terminal that firstly releases the communication that has been held becomes the destination terminal of transfer.
The destination terminal designation receiving section 102 - 10 is adapted to operate for the first transfer method and receive the extension number of the destination terminal of transfer from the origin terminal of transfer.
The transfer hold receiving section 102 - 11 and the release terminal detecting section 102 - 12 are adapted to operate for the second transfer method. The transfer hold receiving section 102 - 11 receives a hold of communication by the origin terminal of transfer and notifies the release terminal detecting section 102 - 12 of that the communication is in a held state. The release terminal detecting section 102 - 12 detects the terminal that is firstly hooked off first as a release terminal.
The post-transfer local IP address detecting section 102 - 13 receives the extension number of the destination terminal of transfer from the destination terminal designation receiving section 102 - 10 when the first transfer method is used whereas the post-transfer local IP address detecting section 102 - 13 receives the extension number of the destination terminal of transfer from the release terminal detecting section 102 - 12 when the second transfer method is used. Then, the post-transfer local IP address detecting section 102 - 13 retrieves the local IP address that corresponds to the received extension number from the extension number versus local IP address correspondence table 102 - 2 .
The record rewriting section 102 - 14 receives information for specifying the record to be rewritten out of the records of the masquerade table 101 - 1 and the local IP address to be written to the record to be rewritten (the local IP address of the destination terminal of transfer) respectively from the record retrieving section 102 - 9 and the post-transfer local IP address detecting section 102 - 13 and rewrites the record to be rewritten among the records of the masquerade table 101 - 1 so as to replace the local IP address in the record by the local IP address of the destination terminal of transfer. As a result of this rewriting, the transfer of communication is realized.
In principle, it is not necessary to rewrite the local port number if the local port number is determined for the type of the communication that is taking place. However, if it is necessary to change the local port number, the record rewriting section also rewrites the local port number by the new local port number on the record to be rewritten among the records of the masquerade table 101 - 1 .
It is necessary to change the local port number, for example, when the local port number is designated by the destination terminal of transfer in the negotiation with the destination terminal of transfer or when the default local port number that is to be used by the destination terminal of transfer is occupied at present.
The record erasing section 102 - 15 detects the extension number or the local IP address of the terminal that has terminated a communication. If the record erasing section 102 - 15 detects the extension number of the terminal that has terminated a communication, the record erasing section 102 - 15 retrieves the local IP address that corresponds to the extension number from the extension number versus local IP address correspondence table 102 - 2 . The record erasing section 102 - 15 also detects the type of the communication that has been terminated or the local port number used for the communication that has been terminated. If the record erasing section 102 - 15 detects the type of the communication that has been terminated, the record erasing section 102 - 15 retrieves the local port number that corresponds to the type of the communication from the local port number storage section 102 - 4 . If, for example, the type of communication is limited to IP telephony and the local port number is fixed, the record erasing section 102 - 15 does not have to detect nor retrieve the local port number but only has to retain the local port number. The record erasing section 102 - 15 then erases the record that describes the detected or retrieved local IP address and the detected or retrieved local port number from the masquerade table 101 - 1 . By doing so, the unnecessary port is closed to improve the security and prevent the unnecessary record from remaining in the masquerade table 101 - 1 .
The presence information storage section 102 - 17 stores information on the current presence or absence of the user at each terminal. It also stores information on the priority of the available terminals for each user. Information for identifying a terminal may be the extension number or the local IP address of the terminal. If a terminal is identified by the extension number thereof, the information stored in the presence information storage section 102 - 17 will be such as illustrated in FIG. 5 . If, on the other hand, a terminal is identified by the local IP address thereof, the information stored in the presence information storage section 102 - 17 will be such as illustrated in FIG. 6 .
The presence information acquiring section 102 - 16 acquires the information to be stored in the presence information storage section 102 - 17 from each terminal by way of the terminal interface 102 - 6 . Alternatively, the presence information acquiring section 102 - 16 may acquire the information to be stored in the presence information storage section 102 - 17 from each terminal by way of local IP network 104 .
If a terminal is identified by the extension number thereof by way of the presence information storage section 102 - 17 , the extension number detecting section 102 - 1 may operate in a manner as described below, using presence information, in addition to the above described operation.
When a call specifying a particular terminal is received and it is made clear from the information stored in the presence information storage section 102 - 17 that the user is currently absent at the terminal, the terminal having the second degree of priority is selected as terminal for receiving the call out of the terminals available to the user and the extension number of the terminal is delivered to the local IP address retrieving section 102 - 3 . This operation is repeated until one of terminals concerned is hooked off or the call gets to the terminal having the lowest degree of priority.
When a call specifying a particular terminal is received and it is made clear from the information stored in the presence information storage section 102 - 17 that the user is supposed to be currently present at the terminal but the terminal is not hooked off within a predetermined period of time (e.g., 30 seconds), the terminal having the second degree of priority is selected as the terminal for receiving the call out of the terminals available to the user and the extension number of the terminal is delivered to the local IP address retrieving section 102 - 3 . This operation is repeated until one of terminals concerned is hooked off or the call gets to the terminal having the lowest degree of priority.
If a terminal is identified by the local IP address thereof in the presence information storage section 102 - 17 , the local IP address retrieving section 102 - 3 may operate in a manner as described below, using presence information, in addition to the above described operation.
When a call specifying a particular terminal is received and, as a result of receiving the extension number from the extension number detecting section 102 - 1 and retrieving the local IP address corresponding to the extension number from the extension number versus local IP address correspondence table 102 - 2 , it is made clear from the information stored in the presence information storage section 102 - 17 that the user is currently absent at the terminal, the terminal having the second degree of priority is selected as terminal for receiving the call out of the terminals available to the user and the local IP address of the terminal is delivered to the record adding section 102 - 5 . This operation is repeated until one of terminals concerned is hooked off or the call gets to the terminal having the lowest degree of priority.
When a call specifying a particular terminal is received and, as a result of receiving the extension number from the extension number detecting section 102 - 1 and retrieving the local IP address corresponding to the extension number from the extension number versus local IP address correspondence table 102 - 2 , it is made clear from the information stored in the presence information storage section 102 - 17 that the user is supposed to be currently present at the terminal but the terminal is not hooked off within a predetermined period of time (e.g., 30 seconds), the terminal having the second degree of priority is selected as the terminal for receiving the call out of the terminals available to the user and the local IP address of the terminal is delivered to the record adding section 102 - 5 . This operation is repeated until one of terminals concerned is hooked off or the call gets to the terminal having the lowest degree of priority.
Now, the operation of the own office side router 101 and that of the call control device 102 at the time of starting a communication will be described below by referring to FIG. 7 .
Firstly, the negotiation section 101 - 3 negotiates with the partner office side server 112 to determine the global port number to be used for the communication (Step S 201 ). Then, the extension number detecting section 102 - 1 detects the extension number of the terminal to be used for the communication (Step S 202 ). Then, the local IP address retrieving section 102 - 3 retrieves the local IP address that corresponds to the extension number detected in Step S 202 from the extension number versus local IP address correspondence table 102 - 2 (Step S 203 ). The local IP address is that of the terminal to be used for the communication. Thereafter, the record adding section 102 - 5 determines the local port number to be used for the communication (Step S 204 ). Then, the record adding section 102 - 5 adds a record describing the corresponding relationship among the global port number determined in Step S 201 , the local IP address retrieved in Step S 203 and the local port number determined in Step S 204 to the masquerade table 101 - 1 (Step S 205 ).
Now, the operation of the own office side router 101 and that of the call control device 102 at the time of transferring the communication will be described below by referring to FIG. 8 .
Firstly, the origin-of-transfer-related information detecting section 102 - 8 detects the extension number of the origin terminal of transfer (Step S 211 ). Then, the origin-of-transfer-related information detecting section 102 - 8 retrieves the local IP address that corresponds to the extension number detected in Step S 211 from the extension number versus local IP address correspondence table 102 - 2 (Step S 212 ). Alternatively, the origin-of-transfer-related information detecting section 102 - 8 may directly detect the local IP address of the origin terminal of transfer in place of the detecting operation of Steps S 211 and S 212 (Step S 213 ). Then, the origin-of-transfer-related information detecting section 102 - 8 detects the local port number that is being used for the communication (Step S 214 ). Thereafter, the record retrieving section 102 - 9 retrieves the information for identifying the record describing the local IP address retrieved in Step S 212 or in Step S 213 and the local port number detected in Step S 214 from the masquerade table 101 - 1 (Step S 215 ). The record is to be rewritten.
Subsequently, the destination terminal designation receiving section 102 - 10 or the release terminal detecting section 102 - 12 detects the extension number of the destination terminal of transfer (Step S 216 ). Then, the post-transfer local IP address detecting section 102 - 13 retrieves the local IP address that corresponds to the extension number of the destination of transfer detected in Step S 216 from the extension number versus local IP address correspondence table 102 - 2 (Step S 217 ). Alternatively, the destination terminal designation receiving section 102 - 10 or the release terminal detecting section 102 - 12 may directly detect the local IP address of the destination terminal of transfer in place of the detecting operation of Steps S 216 and S 217 (Step S 218 ). Then, the record rewriting section 102 - 14 determines the post-transfer local port number (Step S 219 ). Then, the record rewriting section 102 - 14 rewrites the record identified by the identifying information as retrieved in Step S 215 so as to replace the local IP address and the local port number in the record respectively by the local IP address retrieved in Step S 217 or detected in Step S 218 and the local port number determined in Step S 219 (Step S 220 ).
Next, the processing operation of the own office side router 101 and that of the call control device 102 at the time of automatic transfer according to the presence information and by means of the above described first method will be described by referring to FIG. 9 .
Firstly, the negotiation section 101 - 3 negotiates with the partner office side server 112 to determine the global port number to be used for the communication (Step S 201 ). Then, the extension number detecting section 102 - 1 determines whether an extension number is designated (Step S 242 ). If there is not any designated extension number (NO in Step S 242 ), the extension number detecting section 102 - 1 detects the extension number of the terminal that is hooked off first (Step S 243 ) and proceeds to Step S 203 ( FIG. 7 ).
If, on the other hand, there is a designated extension number (YES in Step S 242 ), the extension number detecting section 102 - 1 detects the designated extension number (Step S 244 ) and determines whether the user is present at the terminal having the extension number detected in Step S 244 by referring to the information stored in the presence information storage section 102 - 17 (Step S 245 ). If the user is absent at the terminal having the extension number (YES in Step S 245 ), the processing operation proceeds to Step S 248 . If, on the other hand, the user is present at the terminal having the extension number (NO in Step S 245 ), a call-in bell of the terminal having the extension number detected in Step S 244 is rung up (Step S 246 ). If the terminal is hooked off within a predetermined period of time (NO in Step S 247 ), the processing operation proceeds to Step S 203 ( FIG. 7 ). On the other hand, if the terminal is not hooked off within the predetermined period of time (YES in Step S 247 ), the processing operation proceeds to Step S 248 .
In Step S 248 , it is determined whether the current extension number has the lowest degree of priority by referring to the information stored in the presence information storage section 102 - 17 and, if the degree of priority is the lowest one (YES in Step S 248 ), the processing operation is terminated. Simultaneous call in may be used in place of terminating the processing operation. If the degree of priority is not the lowest one (NO in Step S 248 ), the current extension number is switched to the extension number of the terminal having the next degree of priority by referring to the information stored in the presence information storage section 102 - 17 (Step S 249 ) and the processing operation returns to Step S 245 .
Now, the processing operation of the own office side router 101 and that of the call control device 102 at the time of automatic transfer according to the presence information and by means of the above described second method will be described by referring to FIG. 10 .
Firstly, the negotiation section 101 - 3 negotiates with the partner office side server 112 to determine the global port number to be used for the communication (Step S 201 ). Then, the extension number detecting section 102 - 1 determines whether an extension number is designated (Step S 242 ). If there is not any designated extension number (NO in Step S 242 ), the extension number detecting section 102 - 1 detects the extension number of the terminal that is hooked off first (Step S 243 ) and proceeds to Step S 203 ( FIG. 7 ).
On the other hand, if there is a designated extension number (YES in Step S 242 ), the extension number detecting section 102 - 1 detects the designated extension number (Step S 244 ). Then, the local IP address retrieving section 102 - 3 retrieves the local IP address corresponding to the extension number that is detected in Step S 244 from the extension number versus local IP address correspondence table 102 - 2 (Step S 251 ). Then, it is determined whether the user is present at the terminal having the local IP address retrieved in Step S 251 by referring to the information stored in the presence information storage section 102 - 17 (Step S 252 ). If the user is absent at the terminal having the extension number (YES in Step S 252 ), the processing operation proceeds to Step S 255 . If, on the other hand, the user is present at the terminal having the extension number (NO in Step S 252 ), a call-in bell of the terminal having the extension number detected in Step S 244 is rung up (Step S 253 ). If the terminal is hooked off within a predetermined period of time (NO in Step S 254 ), the processing operation proceeds to Step S 204 ( FIG. 7 ). On the other hand, if the terminal is not hooked off within the predetermined period of time (YES in Step S 254 ), the processing operation proceeds to Step S 255 .
In Step S 255 , it is determined whether the current local IP address has the lowest degree of priority by referring to the information stored in the presence information storage section 102 - 17 and, if the degree of priority is the lowest one (YES in Step S 255 ), the processing operation is terminated. Simultaneous call in may be used in place of terminating the processing operation. If the degree of priority is not the lowest one (NO in Step S 255 ), the current local IP address is switched to the local IP address of the terminal having the next degree of priority by referring to the information stored in the presence information storage section 102 - 17 (Step S 256 ) and the processing operation returns to Step S 252 .
[Embodiment 2]
The call control device 102 acquires information for identifying the record to be rewritten in the masquerade table 101 and then the record is designated by the identifying information so as to rewrite the record in the first embodiment. However, if the own office side router 101 and the call control device 102 communicate with each other according to the uPnP (Universal Plug and Play) Standard, it is not possible to acquire information necessary for identifying the record describing a combination of a particular local IP address and a particular local port number out of the records in the masquerade table 101 - 1 . Additionally, if the own office side router 101 and the call control device 102 communicate with each other according to the uPnP Standard, it is not possible for the call control device 102 to rewrite any record in the masquerade table 101 - 1 .
On the other hand, if the own office side router 101 and the call control device 102 communicate with each other according to the uPnP Standards, it is possible for the call control device 102 to erase a record designated by a global port number from the masquerade table 101 - 1 and add a record describing a desired corresponding relationship of a combination of a global IP address and a pair of a local IP address and a local port number to the masquerade table 101 - 1 .
Therefore, the second embodiment is so adapted that no record in the masquerade table 101 - 1 is rewritten but any desired record can be erased and a new record can be added to replace the erased record in order to achieve an effect equivalent to that of rewriting a record. Once a record is erased, no record corresponding to the erased record exists until a new record is added as replacement. However, no problem arises because no communication takes place between the erasure of a record and the addition of a replacement record.
As shown in FIG. 11 , the own office side router 101 of the second embodiment has a configuration similar to that of the own office side router 101 of the first embodiment
As shown in FIG. 11 , the call control device 102 of the second embodiment is partly identical with the call control device 102 of the first embodiment but partly different from the latter. More specifically, the call control device 102 of the second embodiment has a replica 102 - 50 of the masquerade table, an extension number detecting section 102 - 51 , an extension number versus local IP address correspondence table 102 - 52 , a local IP address retrieving section 102 - 53 , a local port number storage section 102 - 54 , a record adding section 102 - 55 , a terminal interface 102 - 56 , a local IP address assigning section 102 - 57 , an origin-of-transfer-related information detecting section 102 - 58 , a record retrieving section 102 - 59 , a destination terminal designation receiving section 102 - 60 , a transfer hold receiving section 102 - 61 , a release terminal detecting section 102 - 62 , a post-transfer local IP address detecting section 102 - 63 , a record erasing section 102 - 65 , a presence information acquiring section 102 - 66 and a presence information storage section 102 - 67 .
The replica 102 - 50 of the masquerade table has a configuration same as that of the masquerade table 101 - 1 and stores the records same as those of the latter. The replica 102 - 50 of the masquerade table does not have a field for global IP addresses like the masquerade table 101 - 1 . In the following description, it is assumed that there is no field for global IP addresses.
The extension number detecting section 102 - 51 is similar to the extension number detecting section 102 - 1 of the first embodiment.
The extension number versus local IP address correspondence table 102 - 52 is similar to the extension number versus local IP address correspondence table 102 - 2 of the first embodiment.
The local IP address retrieving section 102 - 53 is similar to the local IP address retrieving section 102 - 3 of the first embodiment
The local port number storage section 102 - 54 is similar to the local port number storage section 102 - 4 of Embodiment 1.
At the time of signaling, the record adding section 102 - 55 receives the global IP address and the global port number to be used for the coming communication from the negotiation section 101 - 3 . Note, however, that it is not necessary for the record adding section 102 - 55 to receive the global IP address from the negotiation section 101 - 3 if the global IP address of the own office side router 101 is known or if no field is provided for global IP addresses in the masquerade table 101 - 1 and the replica 102 - 50 of the masquerade table. Additionally, at the time of signaling, the record adding section 102 - 55 receives the local IP address to be used for the coming communication (the local IP address of the terminal to be used for the coming communication) from the local IP address retrieving section 102 - 53 . Furthermore, at the time of signaling, the record adding section 102 - 55 receives the local port number to be used for the coming communication from the local port number storage section 102 - 54 . Then, the record adding section 102 - 55 adds a record describing the global IP address, the global port number, the local IP address and the local port number it received to the masquerade table 101 - 1 and the replica 102 - 50 of the masquerade table. Note, however, that the added record describes only the global port number, the local IP address and the local port number if no field is provided for global IP addresses in the masquerade table 101 - 1 and the replica 102 - 50 of the masquerade table.
Additionally, after the record erasing section 102 - 65 has erased a record, the record adding section 102 - 55 subsequently operates for transfer of communication in a manner as described below. Namely, the record adding section 102 - 55 receives the global port number to be described in the record to be added from the record retrieving section 102 - 59 . Additionally, the record adding section 102 - 55 receives the post-transfer local IP address to be described in the record to be added from the post-transfer local IP address detecting section 102 - 63 . Furthermore, the record adding section 102 - 55 retrieves the local port number to be described in the record to be added from the local port number storage section 102 - 54 depending on the type of communication. Note, however, the local port number to be described in the record to be added may be determined by negotiating with the destination terminal of transfer. Then, the record adding section 102 - 55 adds the received global port number, the received local IP address and the retrieved or determined local port number to the masquerade table 101 - 1 and the replica 102 - 50 of the masquerade table.
The terminal interface 102 - 56 is similar to the terminal interface 102 - 6 of the first embodiment.
The local IP address assigning section 102 - 57 is similar to the local IP address assigning section 102 - 7 of the first embodiment.
The origin-of-transfer-related information detecting section 102 - 58 is similar to the origin-of-transfer-related information detecting section 102 - 8 of the first embodiment.
The record retrieving section 102 - 59 receives the local IP address and the local port number of the origin of transfer from the origin-of-transfer-related information detecting section 102 - 58 and retrieves the record describing the local IP address and the local port number from the replica 102 - 50 of the masquerade table. Then, the record retrieving section 102 - 59 notifies the record erasing section 102 - 65 and the record adding section 102 - 55 of the global port number described in the retrieved record.
The destination terminal designation receiving section 102 - 60 is similar to the destination terminal designation receiving section 102 - 10 of the first embodiment. The transfer hold receiving section 102 - 61 is similar to the transfer hold receiving section 102 - 11 of the first embodiment.
The release terminal detecting section 102 - 62 is similar to the release terminal detecting section 102 - 12 of the first embodiment.
The post-transfer local IP address detecting section 102 - 63 is similar to the post-transfer local IP address detecting section 102 - 13 of the first embodiment.
At the time of transfer of communication, the record erasing section 102 - 65 operates in a manner as described below. Namely, the record erasing section 102 - 65 acquires the global port number, described in the record that describes the local IP address and the local port number of the origin of transfer, from the record retrieving section 102 - 59 . Then, the record erasing section 102 - 65 erases the record that describes the global port number acquired from the record retrieving section 102 - 59 from the masquerade table 101 - 1 and the replica 102 - 50 of the masquerade table.
At the time of end of communication, the record erasing section 102 - 65 operates in a manner as described below. Namely, the record erasing section 102 - 65 detects the extension number or the local IP address of the terminal that has terminated a communication. If the record erasing section 102 - 65 detects the extension number of a terminal that has terminated a communication, the record erasing section 102 - 65 retrieves the local IP address corresponding to the extension number from the extension number versus local IP address correspondence table 102 - 52 . The record erasing section 102 - 65 also detects the type of the communication that has been terminated or the local port number used for the communication that has been terminated. If the record erasing section 102 - 65 detects the type of the communication that has been terminated, the record erasing section 102 - 65 retrieves the local port number that corresponds to the type of the communication from the local port number storage section 102 - 54 . If, for example, the type of communication is limited to IP telephony and the local port number is fixed, the record erasing section 102 - 65 does not have to detect nor retrieve the local port number but only has to retain the local port number. Then, the record erasing section 102 - 65 requests the record retrieving section 102 - 59 to retrieve the global port number described in the record that describes the detected or retrieved local IP address and the detected or retrieved local port number from the replica 102 - 50 of the masquerade table and acquires the global port number retrieved by the record retrieving section 102 - 59 . Then, the record erasing section 102 - 65 erases the record that describes the global port number acquired from the record retrieving section 102 - 59 from the masquerade table 101 - 1 and the replica 102 - 50 of the masquerade table. By doing so, the unnecessary port is closed to improve the security and prevent the unnecessary record from remaining in the masquerade table 101 - 1 and the replica 102 - 59 of the masquerade table.
The presence information acquiring section 102 - 66 is similar to the presence information acquiring section 102 - 16 of the first embodiment.
The presence information storage section 102 - 67 is similar to the presence information storage section 102 - 17 of the first embodiment.
Next, the operation of the own office side router 101 and that of the call control device 102 at the time of starting a communication will be described below by referring to FIG. 12 .
Firstly, the negotiation section 101 - 3 negotiates with the partner office side server 112 to determine the global port number to be used for the communication (Step S 301 ). Then, the extension number detecting section 102 - 51 detects the extension number of the terminal to be used for the communication (Step S 302 ). Then, the local IP address retrieving section 102 - 53 retrieves the local IP address that corresponds to the extension number detected in Step S 302 from the extension number versus local IP address correspondence table 102 - 52 (Step S 303 ). The local IP address is that of the terminal to be used for the communication. Thereafter, the record adding section 102 - 55 determines the local port number to be used for the communication (Step S 304 ). Then, the record adding section 102 - 55 adds a record describing a relationship between the global port number determined in Step S 301 and a pair of the local IP address retrieved in Step S 303 and the local port number determined in Step S 304 to the masquerade table 101 - 1 (Step S 305 ). Then, the record adding section 102 - 55 adds a record identical with the record added to the masquerade table 101 - 1 in Step S 305 to the replica 102 - 50 of the masquerade table (Step S 306 ).
Now, the operation of the own office side router 101 and that of the call control device 102 of the second embodiment 2 at the time of transferring the communication will be described below by referring to FIG. 13 .
Firstly, the origin-of-transfer-related information detecting section 102 - 58 detects the extension number of the origin terminal of transfer (Step S 311 ). Then, the origin-of-transfer-related information detecting section 102 - 58 retrieves the local IP address that corresponds to the extension number detected in Step S 311 from the extension number versus local IP address correspondence table 102 - 52 (Step S 312 ). Alternatively, the origin-of-transfer-related information detecting section 102 - 58 may directly detect the local IP address of the origin terminal of transfer in place of the detecting operation of Steps S 311 and S 312 (Step S 313 ). Then, the origin-of-transfer-related information detecting section 102 - 58 detects the local port number that is being used for the communication (Step S 314 ). Thereafter, the record retrieving section 102 - 59 retrieves the global port number described in the record that describes the local IP address retrieved in Step S 312 or detected in Step S 313 and the local port number detected in Step S 314 from the replica 102 - 50 of the masquerade table (Step S 315 ). Then, the record erasing section 102 - 65 erases the record describing the global port number retrieved in Step S 315 from the masquerade table 101 - 1 (Step S 316 ) and the record describing the global port number retrieved in Step S 315 from the replica 102 - 50 of the masquerade table (Step S 317 ).
Subsequently, the destination terminal designation receiving section 102 - 60 or the release terminal detecting section 102 - 62 detects the extension number of the destination terminal of transfer (Step S 318 ). Then, the post-transfer local IP address detecting section 102 - 63 retrieves the local IP address that corresponds to the extension number of the destination of transfer detected in Step S 318 from the extension number versus local IP address correspondence table 102 - 52 (Step S 319 ). Alternatively, the destination terminal designation receiving section 102 - 60 or the release terminal detecting section 102 - 62 may directly detect the local IP address of the destination terminal of transfer in place of the detecting operation of Steps S 318 and S 319 (Step S 320 ). Then, the record adding section 102 - 55 determines the post-transfer local port number (Step S 321 ). Then, the record adding section 102 - 55 adds a record describing the global port number retrieved in Step S 315 , the local IP address retrieved in Step S 319 or the local IP address detected in Step S 320 and the local port number determined in Step S 321 to the masquerade table 101 - 1 (Step S 322 ) and a record describing the same contents as the record added in Step S 322 to the replica 102 - 50 of the masquerade table (Step S 323 ).
Next, the processing operation of the own office side router 101 and that of the call control device 102 of Embodiment 2 at the time of automatic transfer according to the presence information and by means of the above described first method will be described by referring to FIG. 14 .
It will be clear by comparing FIG. 9 and FIG. 14 that a processing operation same as that of the first embodiment takes place in the second embodiment. Note, however, that the processing operation proceeds to Step S 303 ( FIG. 12 ) after Step S 243 if the outcome of determination in Step S 242 is NO and proceeds to Step S 303 ( FIG. 12 ) if the outcome of determination in Step S 247 is NO.
Now, the processing operation of the own office side router 101 and that of the call control device 102 of the second embodiment 2 at the time of automatic transfer according to the presence information and by means of the above described second method will be described by referring to FIG. 15 .
It will be clear by comparing FIG. 10 and FIG. 15 that a processing operation same as that of the first embodiment takes place in the second embodiment 2. Note, however, that the processing operation proceeds to Step S 303 ( FIG. 12 ) after Step S 243 if the outcome of determination in Step S 242 is NO and proceeds to Step S 304 ( FIG. 12 ) if the outcome of determination in Step S 254 is NO.
To have the person at the partner office hear a melody representing hold, it is only necessary to assign a local IP address and a local port number to a sound source of the melody representing hold and transfer it to the local IP address and the local port number.
The present invention is applicable to transfer of IP communications.
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A communication transfer apparatus and a communication transfer method can transfer communications at low cost without the need of requesting a global IP network to switch any port number. The local internet protocol address of the origin terminal of transfer described in a record relating to a transfer out of the records of the masquerade table that is utilized for an internet protocol masquerade is rewritten as the local internal protocol address of the destination terminal of transfer, while maintaining the global port number of the record.
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FIELD
[0001] The present disclosure relates to a compressible seal for installation in pavement and more particularly a compressible seal for installation in joints in concrete pavement, the machine for installing the seal and the method of installation.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art.
[0003] Installations of concrete pavement including both those with a single large dimension such as driveways and roads and those with two large dimensions such as parking lots and airport aprons expand and contract with the ambient temperature. Such expansion or contraction will frequently result in cracking of the concrete which, without exception, shortens the service life of the concrete. In geographic regions subject to repeated freezing and thawing, the service life of cracked concrete may be dramatically shortened.
[0004] An accepted approach to this problem is to saw kerfs or grooves in the concrete after it has been poured but before it is cured. These kerfs or grooves are generally referred to in the trade as joints and expansion or contraction joints. Because the concrete is generally thinnest at the sawn joints, they act as uniform, linear crack generation sites that cause the concrete to crack in a controlled manner and reduce or eliminate random crazing and cracking. However, the joints themselves need to be protected so that non-compressible materials, e.g., small stones and foreign matter, and water do not fill them. Because these joints are both linear and made during the installation process, they may be, and typically are, readily filled with tar to avoid the harmful effects of materials trapped in the joint and water undergoing the freeze/thaw cycle.
[0005] The tar, itself, however, can be adversely affected by the freeze/thaw cycle. For example, if water collects in the joint below the tar, a freeze cycle will slightly raise the tar and repeated freeze/thaw cycles will force the tar out of the joint. Traffic will then wear away the protruding tar and a small problem may quickly become prematurely deteriorating pavement. Additionally, tar tends to become brittle after two to three years of service. It will thus compress in the winter but fail to expand in the summer, thereby allowing material and water to enter and occupy the joint.
[0006] Furthermore, tar as well as many other liquid sealants, should not be installed when temperatures are below 45° F. (7° C.) or when moisture is present. This limits the conditions during which such sealants can be installed which may delay completion of an installation or repair project. Finally, many sealants put a joint in tension when the concrete contracts in cold temperatures. This tension can increase the rate at which the concrete deteriorates.
[0007] From the foregoing, it can be appreciated that improvements to seals for joints or grooves in concrete slabs would be desirable.
SUMMARY
[0008] The present invention provides a compressible seal for installation in joints in concrete pavement, the machine for installing the seal and the method of installation. The seal is a preformed, cylindrical, closed cell, elastomer. The seal preferably defines a round cross section with a diameter in its relaxed, i.e., uncompressed, state approximately 1.75 times and preferably between about 1.6 and 1.9 times greater than the width of the joint into which it will be installed. The installation machine is a wheeled, hand powered device having a pair of guide wheels which are received within the joint, an aligned installation wheel which installs the seal at the proper depth in the joint and a pair of contra-circulating belts that feed the seal to the installation wheel. The seal of the present invention will prevent concrete pavement from deteriorating prematurely by preventing water and debris from entering and occupying the sawn expansion joint.
[0009] Thus it is an object of the present invention to provide a seal for installation in sawn expansion joints in concrete slabs.
[0010] It is a further object of the present invention to provide a seal for expansion joints in concrete slabs which extends the life of such slabs.
[0011] It is a still further object of the present invention to provide a seal for expansion joints in concrete slabs which prevents entry and accumulation of water and non-compressible material in such joints.
[0012] It is a still further object of the present invention to provide a machine for installing a compressible seal in an expansion joint in a concrete slab.
[0013] It is a still further object of the present invention to provide a hand powered machine for installing compressible seals in expansion joints in concrete slabs.
[0014] It is a still further object of the present invention to provide a method of installing compressible seals in expansion joints in concrete slabs.
[0015] It is a still further object of the present invention to provide a method of installing a compressible seal in an expansion joint of a concrete slab with a hand powered machine.
[0016] Further objects, advantages and areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0017] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0018] FIG. 1 is an enlarged, perspective view of a pavement seal according to the present invention;
[0019] FIG. 2 is a fragmentary, sectional view of a sawn joint in concrete pavement which illustrates the initial installation steps according to the present invention;
[0020] FIG. 3 is a fragmentary, sectional view of a pavement seal installed in a sawn joint in concrete pavement which illustrates the final installation steps according to the present invention;
[0021] FIG. 4 is a perspective view of a machine according to the present invention for installing pavement seal;
[0022] FIG. 5 is an exploded perspective view of a machine according to the present invention for installing pavement seal; and
[0023] FIG. 6 is a bottom view of a machine according to the present invention for installing pavement seal.
DETAILED DESCRIPTION
[0024] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0025] With reference to FIGS. 1 and 2 , a pavement seal according to the present invention is illustrated and generally designated by the reference number 10 . The pavement seal 10 is an aerated elastomer foam having closed cells 11 and a smooth, i.e. non-perforated, and therefore fluid impervious outer skin. The pavement seal 10 preferably defines a round cross section with a nominal diameter, in its relaxed, i.e., uncompressed, state of approximately 0.437 inches+0.0625 inches−0.00 inches (11.1 mm+1.59 mm−0.00 mm). Other multi-sided, for example, six, eight, ten or twelve sided polygonal configurations may be utilized and are within the purview of this invention. This diameter is intended for installation in a standard sawn joint, kerf, channel or groove 12 in concrete pavement 14 having a nominal width of 0.25 inches (6.35 mm). Thus, the diameter of the seal 10 is approximately 1.75 times the width of the joint or groove 12 or, stated inversely, the width of the joint or groove is approximately 57% of the diameter of the pavement seal 10 . This size relationship has been found to provide excellent seal performance in view of the expansion and contraction of the pavement 14 during seasonal temperature changes.
[0026] A joint or groove 12 having a sawn width of 0.25 inches may typically open to a maximum width of 0.345 inches (8.76 mm) and close to a minimum width of 0.165 inches (4.19 mm) due to thermal expansion and contraction of the concrete pavement 14 . Ideally, the width of the joint or groove 12 will be approximately 57% of the uncompressed diameter of the pavement seal 10 ; preferably, the width of the joint or groove 12 will be in the range of from 52% to 62% of the uncompressed diameter of the pavement seal 10 and the width of the joint or groove 12 in a range of 45% to 70% of the uncompressed diameter of the pavement seal 10 is functional. It will be appreciated that smaller and larger diameter seals 10 may be utilized with correspondingly narrower and wider joints or grooves 12 if the ideal 57% relationship, or the preferred or functional ranges recited directly above, are adhered to. For example, a sawn joint or groove 12 having a width of 0.375 inches (9.52 mm) would ideally receive a seal 10 having an uncompressed diameter of approximately 0.655 inches (16.70 mm)
[0027] The pavement seal 10 is a preformed cylinder of indefinite length. The pavement seal 10 , as noted, includes entrained air in closed cells 11 . While polychloroprene compounds have been found to provide good performance, a selection of elastomers, including polychloroprene, styrene butadiene, acrylonitrile butadiene, polyethylene, polyvinyl chloride, ethylene propylene diene and blends of these materials are also suitable. The pavement seal 10 preferably has a compression deflection, i.e., spring, rate of approximately 2 pounds per inch at 15% compression, a specific gravity of 0.6±0.1 and a density of 37.44 pounds per cubic foot ±3.74. The pavement seal 10 preferably exhibits a Shore A durometer measurement of 25±5.
[0028] The pavement seal 10 according to the present invention is rugged, exhibiting a breaking strength of approximately 200 p.s.i. (1.4 mPa) with an elongation at break of 150%. It will be appreciated that the pavement seal 10 may be manufactured, typically by an extrusion process, in continuous lengths which are cut into pieces several hundred feet in length for storage and shipment on spools and then cut to desired lengths at the installation site as will be described in more detail below.
[0029] Referring now to FIGS. 4 and 5 , a pavement seal installation machine is illustrated and designated by the reference number 20 . The pavement seal installation machine 20 includes a rectangular lower frame assembly 22 typically and preferably fabricated of welded steel or aluminum box beams. The rectangular lower frame assembly 22 includes a front transverse beam 24 , a rear transverse beam 26 , a right side beam 28 and a left side beam 32 . Received within four blind sockets 34 mounted on the tops of the right side beam 28 and the left side beam 32 and releasably secured by clevis pins 36 is an upper, tubular frame assembly 40 . The tubular frame assembly 40 may be fabricated of a plurality of straight tubular sections 42 and right angle end fittings 44 or it may include a pair of U-shaped hoops each formed from a single piece of tubing.
[0030] Extending between the upright tubular sections 42 at the front of the machine 20 is a horizontal beam or tube 46 which pivotally receives and supports a T-bar handle 48 . A pair of adjustable stops 50 may be moved vertically along the front upright tubular sections 42 and secured thereto to set the height of the horizontal tube 46 and the T-bar handle 48 . Extending between the upright tubular sections 42 at the back or rear of the machine 20 is a rectangular panel 52 which locates and supports a pivotable caster 54 on its outside face. The rectangular panel 52 is preferably located to provide a stop for the T-bar handle 48 when it is in a stowed position as illustrated in FIG. 4 . So stowed, the T-bar handle 48 is not only readily accessible but it is also maintained in a position away from the operating mechanism of the machine 20 .
[0031] Positioned within the lower frame assembly 22 and capable of both vertical motion and front to back motion, that is, motion parallel to the right and left side beams 28 and 32 , is a sub-frame or chassis 60 . The chassis 60 is coupled to the lower frame assembly 22 by a right adjustment assembly 62 A and a left adjustment assembly 62 B. Since the adjustment assemblies 62 A and 62 B are identical except for their mirror image construction and arrangement, only the right adjustment assembly 62 A will be described.
[0032] The right adjustment assembly 62 A includes a narrow, L-shaped bracket 64 secured to and extending upwardly from the right side beam 28 . The narrow, L-shaped bracket 64 includes a threaded opening 66 which receives a complementarily threaded shaft 68 having a hand or finger engageable handle or knob 70 . At the opposite end of the threaded shaft 68 and secured thereto is a chain drive sprocket 72 . The chain drive sprocket 72 receives and drives a chain 74 that engages and drives a first, driven chain sprocket 76 and a second, driven chain sprocket 78 . The first, driven chain sprocket 76 rotates on a first threaded rod 82 and the second, driven chain sprocket 78 rotates on a second threaded rod 84 . The threaded rods 82 and 84 are received within complementarily threaded stationary nuts 86 or similar threaded components which are secured to the right side beam 28 . Openings (not illustrated) in the top of the right side beam 28 aligned with the stationary nuts 86 allow the threaded rods 82 and 84 to extend into the right side beam 28 . Resting upon the upper faces of the first and second driven chain sprockets 76 and 78 is a large, L-shaped bracket 90 A which extends upwardly from the chassis 60 . The large, L-shaped bracket 90 A defines a pair of elongate slots 92 which receive the respective pair of threaded rods 82 and 84 . Disposed on each of the threaded rods 82 and 84 above the upper surface of the large, L-shaped bracket 90 A is a washer 94 and a wing nut 96 .
[0033] To adjust the front to rear position of the chassis 60 relative to the lower frame assembly 22 , the wing nuts 96 of both the right adjustment assembly 62 A and the left adjustment assembly 62 B are loosened and the chassis 60 is moved as necessary and the wing nuts 96 are then tightened. To adjust the height of the chassis 60 relative to the lower frame assembly 22 , the wing nuts 96 of both the right adjustment assembly 62 A and the left adjustment assembly 62 B are loosened and the handles or knobs 70 of the adjustment assemblies 62 A and 62 B are rotated, clockwise to lower the chassis 60 or counter-clockwise to raise the chassis 60 . When the chassis 60 has reached the desired height relative to the lower frame assembly 22 , the wing nuts 96 are tightened. It will be appreciated that in addition to providing height adjustment, the threaded shaft 68 , the chain drive sprocket 72 , the chain 74 , the first, driven chain sprocket 76 , the second, driven chain sprocket 78 and the threaded rods 82 and 84 maintain the chain 74 in a horizontal plane during height adjustment which obviates binding and chain misalignment.
[0034] The sub-frame or chassis 60 includes the right and left large, L-shaped brackets 90 A and 90 B which are connected by a transverse U-shaped strap 102 . Also extending between the large, L-shaped brackets 90 A and 90 B is a rotatable shaft 104 having ends which are received within a pair of bearing assemblies 106 . An installation wheel 108 having a plurality of teeth 110 disposed about its periphery is secured to the middle of the shaft 104 for rotation therewith and a driven chain sprocket 112 is secured to the rotatable shaft 104 adjacent one of the bearing assemblies 106 .
[0035] At the front of the lower frame assembly 22 is disposed a front guide assembly 120 . The front guide assembly 120 includes a forwardly and downwardly extending bar or arm 122 which is secured to the inside face of the right side beam 28 . At the forward end of the bar or arm 122 is a transversely oriented shaft 124 which extends slightly beyond the middle of the lower frame assembly 22 . On the shaft 124 at the transverse center of the lower frame assembly 22 is a first or forward freely rotatable guide wheel 126 .
[0036] At the front or forward end of the lower frame assembly 22 , in the right side beam 28 and the left side beam 32 , are a pair of aligned bearings 128 which receive a front drive axle 130 . Secured to opposite ends of the front drive axle 130 are a pair of front or drive wheels 132 . Also secured to and rotating with the front drive axle 130 is a first chain drive sprocket 134 which engages and drives a first chain 136 . The first chain 136 engages and drives a first idler sprocket 138 . The first idler sprocket 138 is secured to a stub shaft 142 which is received within a vertically moveable bushing 144 . The vertical position of the bushing 144 and thus of the stub shaft 142 is adjustable by a threaded shaft 146 which may be fixed in place in an elongate slot 148 in a vertical mounting bracket 152 by a jam nut 154 .
[0037] Secured to the stub shaft 142 on the opposite side of the vertical mounting bracket 152 is a second idler sprocket 156 which engages and drives a second chain 158 . The second chain 158 engages and drives the driven chain sprocket 112 on the shaft 104 . It will therefore be appreciated that motion of the pavement seal installation machine 20 along a surface will rotate the pair of front or drive wheels 132 which will rotate the front drive axle 130 and the first chain drive sprocket 134 . In turn, the first drive chain 136 and the second drive chain 158 will circulate, rotating the driven chain sprocket 112 and the toothed installation wheel 108 on the shaft 104 . The diameters of the front or drive wheels 132 , the chain sprockets 134 , 138 , 156 and 112 and the installation wheel 108 are such that the surface speed of the installation wheel 108 is slightly faster than the surface speed of the front or drive wheels 132 .
[0038] Referring now to FIGS. 5 and 6 , secured to the front transverse beam 24 by any suitable means such as a threaded stud are a pair of right and left speed increasing gear boxes 160 A and 160 B. The speed increasing gear boxes 160 A and 160 B preferably provide a drive ratio of 2 to 3, that is, two turns at the input result in three turns at the output. It should be understood that this ratio may be adjusted up or down to accommodate other variations in the installation machine 20 . The right and left gear boxes 160 A and 160 B are coupled to and driven by the front drive axle 130 . The gear boxes 160 A and 160 B are opposite in sense. As viewed in FIG. 5 , with clockwise (forward) rotation of the front wheels 132 and the front drive axle 130 , the output of the right gear box 160 A is counter-clockwise when viewed from above and the output of the left gear box 160 B is clockwise when viewed from above.
[0039] The outputs of the gear boxes 160 A and 160 B are provided to right and left gears or cogged wheels 162 A and 162 B, respectively, which engage a respective pair of right and left timing belts 164 A and 164 B. The right timing belt 164 A engages and circulates counter-clockwise about a right, first idler wheel 166 A and a right, second, equal diameter idler wheel 168 A. The right, first idler wheel 166 A and the right, second idler wheel 168 A are freely rotatably disposed on sleeve bearings and stub shafts 170 A secured to a right U-shaped plate 172 A which, in turn, is attached to the right L-shaped bracket 90 A through an intermediate member 174 A by suitable fasteners.
[0040] The left timing belt 164 B engages and circulates clockwise about a left, first idler wheel 166 B and a left, second, equal diameter idler wheel 168 B. The left, first idler wheel 166 B and the left, second idler wheel 168 B are freely rotatably disposed on sleeve bearings and stub shafts 170 B secured to a left U-shaped plate 172 B which, in turn, is attached to the left L-shaped bracket 90 B through an intermediate member 174 B by suitable fasteners. The opposed surfaces of the right timing belt 164 A and the left timing belt 164 B are spaced apart a distance which is greater than the thickness of the toothed installation wheel 108 to allow it free motion therebetween but less than the diameter of the pavement seal 10 so that they engage and compress it.
[0041] The opposed rotation and travel of the timing belts 164 A and 164 B and their spacing at the middle of the machine 20 draws the pavement seal 10 (illustrated in FIG. 1 ) through the machine 20 as will be more fully described below. The drive ratios from the front drive wheels 132 , through the gear boxes 160 A and 160 B and through the cogged wheels 162 A and 162 B to the timing belts 164 A and 164 B are such that the surface speed of the front drive wheels 132 is the same as the surface speed of the timing belts 164 A and 164 B. Accordingly, the pavement seal 10 is drawn into the installation machine 20 and fed to the toothed installation wheel 108 without either axial stretching or compression.
[0042] On the outside faces of the right side beam 28 and the left side beam 32 are mounted a pair of rear wheels 176 . The rear wheels 176 are rotatably disposed upon stub shafts or axles 178 which are secured to the respective beams 28 and 32 . Disposed in the middle of the rear transverse beam 26 in alignment with the toothed installation wheel 108 and the front rotatable guide wheel 126 is a rear guide wheel 180 rotatably mounted in a clevis 182 . It will be appreciated that the front rotatable guide wheel 126 , the toothed installation wheel 108 and the rear rotatable guide wheel 180 all cooperate to maintain the installation machine 20 in alignment with a joint or groove 12 in the concrete pavement 14 to facilitate proper and efficient installation. Furthermore, the rear guide wheel 180 sets the seal 10 to the final desired depth in the joint or groove 12 .
[0043] The installation process will now be described in connection with FIGS. 2 , 3 and 4 . Joints or grooves 12 are cut by a saw (not illustrated) in the concrete pavement 14 . The joints or grooves 12 are cut to a minimum of 25% of the thickness of the concrete pavement 14 and preferably to a depth of 33% of the thickness. After the necessary joints or grooves 12 have been cut in the pavement 14 and any debris has been blown out of the joints or grooves 12 with compressed air from an air compressor or pressurized water from a power washer through, for example, a nozzle 16 , a length of the pavement seal 10 according to the present invention is laid along the full length of the joint or groove 12 .
[0044] Next, a lubricating, soapy solution of, for example, undiluted liquid hand dish washing soap or vegetable oil soap is applied by a spray head 18 to the pavement seal 10 or the walls of the joint or groove 12 immediately prior to installation of the seal 10 . Then, the front rotatable guide wheel 126 , the toothed installation wheel 108 and the rear rotatable guide wheel 180 are placed or located in the joint or groove 12 with the front guide wheel 126 toward the direction of installation and travel. The pavement seal 10 is then inserted between the timing belts 164 A and 164 B and the installation machine 20 is moved by hand along the joint or groove 12 . The toothed installation wheel 108 rotates and installs the pavement seal 10 to the proper depth of between 0.125 inches (3.17 mm) and 0.50 inches (12.7 mm) in the joint or groove 12 . It is highly desirable that the pavement seal 10 experiences no more than approximately 4% stretch or elongation during the installation process and preferably less.
[0045] As stated, the pavement seal 10 should be installed with its upper surface between about 0.125 inches (3.17 mm) and 0.50 inches (12.7 mm) below the surface of the concrete pavement 14 . To achieve this preferred depth of installation, it may be necessary to adjust the height of the toothed installation wheel 108 and the second guide wheel 180 relative to the top surface of the pavement 14 , that is, the depth of penetration of the toothed installation wheel 108 and the second guide wheel 180 into the joint or groove 12 . The toothed installation wheel 108 is adjusted by using the right and left adjustment assemblies 62 A and 62 B, as described above. The height of the second guide wheel 180 is adjusted by repositioning the clevis 182 .
[0046] As noted above, pavement seals having both larger and smaller diameters than the diameter of the pavement seal 10 recited herein for correspondingly larger and smaller joints or grooves are within the purview of the present invention. Preferably, the width of the joint or groove into which the pavement seal will be installed is approximately 57% of the diameter of the pavement seal in its uncompressed (uninstalled) state. However, as noted above, the pavement seal may be installed in a joint or groove 12 having a width a little as 45% to as much as 70% of the uncompressed diameter of the pavement seal with acceptable results.
[0047] Before and after installation of the pavement seal 10 , the installation machine 20 is readily moved about by tipping it onto the two rear wheels 176 (which extend beyond the ends of the side beams 28 and 32 ) and the caster 54 . The T-bar handle 48 may then also be utilized to conveniently maneuver the installation machine 20 . So disposed, the likelihood of damage to the guide wheels 126 and 180 and the toothed installation wheel 108 is minimized. Moreover, if care is taken to tip the installation machine 20 upright over the joint or groove 12 such that the guide wheels 126 and 180 and the toothed installation wheel 108 are received within the joint or groove 12 , little or no adjustment or resetting of the adjustment assemblies 62 A and 62 B should be necessary and the likelihood of damage to the wheels 108 , 126 and 180 is further reduced.
[0048] It should be appreciated that in addition to facilitating height adjustment of the chassis 60 relative to the frame 22 , the front to back adjustment also provided by the adjustment assemblies 62 A and 62 B facilitates tightening, loosening and replacement of the timing belts 164 A and 164 B.
[0049] The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from either the spirit or the scope of the invention or the following claims.
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The present invention provides a compressible seal for installation in joints in concrete pavement, the machine for installing the seal and the method of installation. The seal is a preformed, closed cell, elastomeric cylinder or rope. The seal defines a round cross section in its relaxed, i.e., uncompressed, state somewhat larger than the joint into which it will be installed. The installation machine is a wheeled, hand powered device having a first guide wheel which is received within the joint, an aligned installation wheel which installs the seal in the joint, a second guide wheel which ensures that the seal is at the proper depth in the joint and a pair of contra-circulating belts which feed the seal to the installation wheel.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to firearms, and more particularly to a semiautomatic pistol having a breechbolt slidable and rotatable on the receiver.
2. Description of the Related Art
The design of the semiautomatic pistol has not changed significantly since the introduction of the Colt .45 Model 1911 in the early 1900s. Since that time, others have made some minor modifications in the basic design, but nothing of a fundamental nature.
In the Model 1911 pistol, cartridges are stored in an ammunition clip, which is inserted into the grip of the pistol. Cocking and firing of the gun are accompanied by movement of an external slide, and spent shells are ejected from the top of the gun, where they can be distracting to the shooter. The slide travels a distance on the order of two inches each time the gun is fired, and this limits the cycle time or rate at which successive rounds can be fired. Sights are mounted on the moving slide, which makes aiming difficult, and the sliding mechanism and other parts of the action are subject to substantial wear and mechanical failure.
In case of the gun being of a target type, it is nearly impossible to get a secure aim with recoiling sights. Therefore sights should be mounted on places free from recoiling, shaking and locations subject to substantial wear and mechanical failure. On a gun with a reciprocating slide, the sights should be at a most forward location and a most rearward location of the gun on safe and secure places. Given the aforementioned, there would only be one way to mount the breechblock, i.e., from the sides, since front and rear portions are closed.
Thus, a semiautomatic pistol solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The semiautomatic pistol has a rigidly fixed barrel and sights attached thereto. The body of the pistol is receives a breechbolt that moves axially in line with the fixed barrel and then rotatably with respect to the fixed barrel axis. Cartridges are transferred from the magazine up to the action in the breechbolt, and spent cartridge cases are ejected out of the eject port. Sights are attached to front and rear sections of the fixed barrel.
These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 side view of the semiautomatic pistol according to the present invention.
FIG. 2 is a side view of the semiautomatic pistol according to the present invention, showing slider action according to the present invention.
FIG. 3 is a perspective view of the semiautomatic pistol according to the present invention, showing the breechbolt rotated.
FIGS. 4A and 4B show exploded perspective views of subassemblies of the semiautomatic pistol according to the present invention.
FIG. 5 is a partial side view of the semiautomatic pistol according to the present invention, broken away and partially in section to show details thereof.
FIG. 6 is a partial side view of the semiautomatic pistol according to the present invention, broken away and partially in section with the breechbolt drawn.
FIG. 7 is a perspective view of the breechbolt of a semiautomatic pistol according to the present invention having alternative retainer elements.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1-4B , the present invention relates to a semiautomatic pistol 60 , including a barrel 120 having a hollow tubular front portion 400 and a rear portion formed by a top wall 402 that extends away from the front portion 400 of the barrel 120 . A barrel retainer pin 160 is used to attach a rigid receiver 100 to the barrel 120 to form a longitudinally extending eject port 122 . A breechbolt slide post 100 a extends downward from the barrel rear portion top wall 402 into the receiver 100 at the rear of the eject port 122 .
A breechbolt 130 being slidably and rotatably mounted around the breechbolt slide post 100 a is mounted within the receiver 100 and top wall 402 . The breechbolt 130 includes a front face having a recess 130 c receiving the forward end of a recoil spring guide 53 , with the rear end of the recoil spring guide 53 received within a recoil spring compressor 52 fixedly mounted to rear distal end of the receiver 100 to bias the breechbolt 130 in a forward orientation.
A recoil spring 54 may be wound about the guide 53 and captured between the front face 130 c of breechbolt 120 and the compressor 52 by retaining an axially engaged recoil spring plug 55 with a recoil spring plug retaining pin 56 that slidably mounts into a vertical bore in breechbolt 130 . Internal walls of the breechbolt side arms 130 b form an opening capable of receiving a firing pin plunger 50 and firing pin spring 51 therethrough, the firing pin plunger 50 being in an axially sliding relationship relative to the breechbolt 130 .
Between the front and rear of breechbolt 130 are indentations in the breechbolt side arm interior walls that form a turn recess 130 a . Turn recess 130 a functions as a pivot point for axial rotation of the breechbolt 130 . Firing pin 49 is movably disposed inside front portion of the breechbolt 130 for operable communication with the firing pin plunger 50 .
An extractor 46 is biased forwardly by an extractor plunger 47 that captures an extractor spring 48 between the extractor plunger 47 and a forward end of the breechbolt face for operable communication of a cartridge head directed into a bore of barrel 120 .
A top wall lever aperture 404 is disposed in the top wall 402 . Lever 10 is disposed inside the top wall lever aperture 404 , the lever being pivotally attached to the top wall 402 by lever axis pin 190 . The lever 10 is biased by a lever plunger 11 in combination with a lever plunger spring 12 . Adjusting pin 22 in combination with adjusting pin retainer ring 24 is in operable communication with lever 10 in order to adjust pivotal travel distance of the lever 10 . The breechbolt 130 preferably has at least one longitudinally disposed groove 130 d that the lever 10 can slidably engage to guide reciprocal motion of the breechbolt 130 during firing of the gun 60 .
A hammer 40 capable of engaging firing pin plunger 50 is pivotally mounted in the receiver 100 about a hammer axis pin 38 and is disposed in a position for engagement with sear 33 in a cocked orientation of the hammer 40 . Ejector 39 is coaxially mounted with the hammer 40 . Adjusting pin 23 in combination with adjusting pin retainer ring 25 is in operable communication with the hammer assembly in order to limit cocking travel of hammer 40 . A hammer strut 42 is pivotally disposed on the hammer 40 and is retained by hammer strut axis pin 41 . A hammer stop pin 43 is disposed through the receiver to arrest forward pivotal motion of the hammer 40 during firing action. Sear 33 is pivotally mounted in the receiver 100 and retained by sear axis pin 32 while being biased by coaxially mounted sear spring 34 . A main spring 18 is wound about a hammer plunger 19 at an upper end of the main spring 33 and wound about a magazine latch plunger 17 at a lower end of the main spring 33 . A magazine latch 16 is configured to abut against the free end of magazine latch plunger 17 to retain a magazine when the pistol 60 is fully assembled. A hollow main spring housing 44 is attached to the receiver 100 by a main spring housing retaining pin 45 and may extend downward from the receiver 100 at an angle. The main spring 18 , hammer plunger 19 and magazine latch plunger 17 are disposed through a mainspring washer 15 and inside the hollow main spring housing 44 . When handle 140 is attached to receiver 100 a lower handle retainer pin 14 being disposed through the handle 140 and the main spring housing 44 retains handle 140 and magazine latch 16 in operable position.
Receptacles 20 and 21 are disposed on the receiver 100 and slidingly engage top of handle 140 for a secure friction fit attachment to the receiver 100 . The handle 140 houses a trigger 27 pivotally about a trigger axis pin 26 , the trigger axis pin 26 being disposed in the receiver 100 . The trigger includes a trigger spring 31 having a trigger spring plunger 30 at its forward end mounted between the trigger and the receiver 100 in order to bias the trigger 27 downwardly in communication with a forward end of a trigger bar 29 . Forward end of trigger bar 29 is pivotally retained in the trigger 27 by trigger bar axis pin 28 . The trigger bar 29 extends rearward of the trigger 27 inside handle 140 . Extreme rear of trigger bar 29 has a boss that engages the sear 33 to displace the sear 33 relative to the hammer 40 permitting the hammer 40 to engage the firing pin plunger 50 directing the firing pin 49 forwardly into engagement with a cartridge (not shown) positioned within a bore of barrel 120 .
An elongate safety latch 35 is pivotally disposed in the receiver 100 to engage the trigger 27 in a safety position that prevents firing of the pistol 60 . A breechbolt stop 36 having a breechbolt stop spring 37 is attached to the receiver 100 in a position for operable communication with the breechbolt 130 to limit travel of the breechbolt 130 .
The handle 140 is further secured to the receiver by upper handle retainer pin 13 and can receive an automatic pistol magazine of a type known in the art.
A rear sight 180 , as well as a front sight 170 , are aligned and mounted to respective rear and front portions of barrel 120 respectively. Advantageously, when firing the gun 60 neither the rear sight 180 nor the front sight 170 moves with respect to the barrel 120 or receiver 100 .
As shown in FIGS. 5-7 an alternatively configured breechbolt 521 may be used. A top strap 501 is attached to and extends rearward away from barrel 301 . The top strap 501 has a breechbolt retainer guiding groove 505 a and a breechbolt retainer lock rotating recess 505 b . Top strap 501 and receiver 591 attach to form a bottom and top enclosure having an open sided eject port 708 . A breechbolt retaining assembly 512 is mounted in the breechbolt for slidable engagement with receiver 591 and comprises L shaped breechbolt retainer body 512 a having breechbolt retainer detent grooves 512 c . A breechbolt lock 512 b has a lateral slot that engages the retainer lever 512 . A breechbolt retainer firing pin crosscut 512 d is disposed in the breechbolt retainer lock 512 b . Recoil spring plugs 527 a and 528 a are held by retainer lever 512 . Recoil springs 525 a and 526 a are wound around recoil spring plugs 527 a and 528 a respectively. The entire recoil assembly is disposed within the breechbolt 521 with the recoil springs 525 a and 526 a having one end fixedly attached to a rear portion of the receiver 591 to provide spring bias to the breechbolt 521 . The breechbolt 521 is slidably engaged between the top strap 501 and the receiver 591 . Interior portion of breechbolt 521 has a solid lateral piece 521 a joining the sidewalls. The breechbolt retaining detent grooves 512 c of the retaining assembly 512 being attached to the breechbolt 521 allow the breechbolt 521 to slidably engage a correspondingly grooved receiver 591 . Sidewalls of breechbolt 521 have indentations that form a turn recess 530 a for pivotal movement of the breechbolt 521 during firing action. Axially extending slidable firing pin 533 is disposed within the breechblock 521 and biased by firing pin spring 534 . Extractor 536 is pivotally disposed within the breachbolt 521 to provide extraction of spent cartridges through the eject port 708 .
It is to be understood that the present invention is not limited to the embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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The semiautomatic pistol has a rigidly fixed barrel and sights attached thereto. The body of the pistol receives a breechbolt that moves axially in line with the fixed barrel. Cartridges are transferred from the magazine up to the action in the breechbolt, and spent cartridge cases are ejected out of a side eject port disposed on the pistol. Dismounting of the breechbolt is facilitated by a pivotal dismounting post at the rear of the eject port.
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TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to an additive for domestic washing processes. It also relates to a process for treating fibres in a domestic washing process.
BACKGROUND OF THE INVENTION
[0002] In domestic washing processes, after washing with detergent to remove dirt from the clothing, the clothes are usually rinsed with products for special treatment, called products for the finishing treatment of washed clothes. For example, such as special treatment products usually used with fabric softeners which in turn incorporate some perfumed substance. However, in the case of perfumed softeners, this finishing cycle does not, on many occasions, have a long-lasting effect, with the washed clothes very quickly ceasing to emit the perfume they were impregnated with.
[0003] With the aim of prolonging the emission of perfume in fabric softeners, the perfume is contained in said softener in the form of microcapsules whose nucleus contains the desired perfume. An example of this type of fabric softener is disclosed in patent ES 2063241, wherein microcapsules and the fabric softeners containing them are described, to improve the finishing cycle of the clothing and prolonging their scent and feeling of freshness. Also, in WO 0162376, micro and nanocapsules are disclosed which are incorporated into detergents and cleaning products, for example, for the treatment of fabrics, such as mild detergents, stain removers, universal detergents, etc.
[0004] The microcapsules, or micrometric-sized capsules comprised of a nucleus covered in a coating suitable for holding the nucleus inside, are being used in many fields of the art. One of these is the finishing treatment of textiles or fibrous materials to give the fibres the required properties, for example, to make ironing easier, to make the fibres fire-resistant or water-proof, or to release a perfume or cosmetic agent of interest.
[0005] In this latter case, garments can be found on the market that incorporate a microencapsulated moisturizing and/or tonic agent, such as, for example, underwear with a microencapsulated firming agent which is released by the effect of rubbing against the wearer's skin and which comes into contact with the skin, being absorbed and, hence, releasing its effect. The use of microcapsules is done at manufacturing level, generally before the garments, that are to incorporate the microcapsules with the agent of interest, are made. An example of this is disclosed WO 03026594, wherein ginger oil is encapsulated in microcapsules which are applied to fabrics, more specifically in the manufacture of tights and/or socks, the ginger oil being released when it rubs against the skin, which enables improved microcirculation and reduces swelling of the lower extremities.
[0006] The problem with said garments is that once the microencapsulated active agent has been completely released, the garments or fibrous materials become conventional garments or fibres without the desired effects, because the microcapsules have opened and the reserves of the agent of interest used up, or because said agent has diffused through the barrier or coating of the microcapsules.
[0007] In an attempt to provide and prolong the emission of a determined perfume, U.S. Pat. No. 4,234,627 discloses a composition for the process of domestic prewashing or washing which comprises a granular textile treatment mixture and an adjuvant for pre-washing or washing. The granular mixture contains some microcapsules and a so-called microcapsule transfer agent, which in practice refers to an organic material of the type conventionally used as domestic-use softening agents. However, in this case, the granular component with microcapsules is suitable for the pre-washing and washing process and subsequent drying of the clothes, incorporating a detergent or surfactant which is soluble in water. Said composition is sufficient for perfuming the garments that are washed, but it is a complex composition which has the added drawback that the user has to use the detergent or softener accompanying the granular mix.
[0008] The additive object of the present invention provides new solutions to said problems, while offering notable advantages to the state of the art.
EXPLANATION OF THE INVENTION
[0009] The additive for domestic washing processes, for incorporation in the process after washing and rinsing, is characterized in that it is comprised of a microencapsulated product which is either a cosmetic, a pharmacological drug, an evaporable product or a combination thereof, the microcapsule coating being comprised of a cationic compound.
[0010] According to another characteristic of the invention, the additive is in the form of a monodose.
[0011] The additive according to the invention is also characterized in that it is in liquid form.
[0012] According to another characteristic of the additive of the invention, the cosmetic product is selected independently from among a moisturizing compound, an ultra-violet ray protector, a toner, a product for reducing the effects of stress on the skin, an anti-wrinkle compound, a deodorant, a compound to slow hair-growth and/or a whitening compound.
[0013] The additive according to the invention comprises a pharmacological product which is selected independently from among a painkiller, a bactericide agent, an epulotic agent and/or essence of eucalyptus.
[0014] According to another characteristic of the invention, the microcapsule coating is comprised of starch that has been subjected to a chemical modification to give it a positive charge, for example, via quaternization.
[0015] Another object of the invention is a process for treating fibres in a domestic washing process characterized in that after the stages of washing with detergent and rinsing of the fibres, one or more additives, separate from one another, are added, which are comprised of a microencapsulated product selected from among a cosmetic, a pharmacological drug, an evaporable product or a combination thereof, the microcapsule coating being comprised of a cationic compound.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The additive for domestic washing processes, for use once the clothes have been washed and rinsed, is designed to be incorporated in conventional, domestic washing machines, as an entity or additive separate from any fabric softener or detergent. The additive according to the invention is comprised of the desired product for impregnating the clothes, and which forms the nucleus of some microcapsules with a cationic coating. Said microcapsules are produced by the usual procedures used and known by a person skilled In the art, such as, for example, by coacervation techniques.
[0017] The additive for domestic washing processes is preferably presented in the form of a single-dose, which is placed in the washing-machine compartment used for fabric softeners or other products for the final treatment of clothes.
[0018] In addition, the additive is preferably supplied in the form of a suspension of the microcapsules in an inert liquid, such as water with an acid compound to enhance the cationic character of the microcapsule coating. In such a case, a preferred compound is one which comprises between 0.1% and 40% by weight of the microencapsulated product; between 1.0% and 20% by weight of cationic coating; and an adequate quantity for 100% by weight of water, which may comprise other dissolved compounds, such as, for example, hydrochloric acid.
[0019] The cationic coating used is a polysaccharide such as starch, or any other type of fecula, which must have a positive charge in order to be able to attach itself to the fibres of the clothing, which generally have negative charges. For example, in the case of using starch, it may have positive charges via a treatment of quaternization with dimethyl sulphate.
[0020] Among the products forming the nucleus of the microcapsules, cosmetics, pharmacological drugs or evaporable products are selected, the evaporable products being insect repellents or air fresheners.
[0021] Some examples of microencapsulated products in additives for the domestic washing process according to the invention will now be presented.
[0022] When treatment of the clothing with the additive is trying to achieve the effect of providing the fibres with the capacity to act as a transporter of a cosmetic product, the microcapsules with a coating with a cationic compound contain a moisturizing compound, such as extract of Aloe Vera; an ultra-violet ray protector, a toner, a product for reducing the effects of stress on the skin, for example, a free-radicals captor; an anti-wrinkle compound; a deodorant; a compound to slow hair-growth; or a whitening compound.
EXAMPLE 1
Additive With Cosmetic Product With Moisturizing Effect
[0023] 60%-85% by weight of water of the total additive weight.
[0024] Microcapsules comprised of a cationic coating with a percentage weight, with respect to the total additive weight, of between 5% and 10%; and a nucleus of between 10% and 30% by weight of extract of Aloe vera and Chitosan, with respect to the total additive weight.
EXAMPLE 2
Additive With Cosmetic Product With Photoprotective Effect
[0025] 65%-85% by weight of acidified water, of the total additive weight.
[0026] Microcapsules comprised of a cationic coating with a percentage weight, with respect to the total additive weight, of between 10% and 20%; and a nucleus of between 5% and 15% by weight of extract of Aloe Vera; Chitosan and Cinnamate, with respect to the total additive weight.
EXAMPLE 3
Additive With Cosmetic Product With Anti-Cellulite Effect
[0027] 70%-94% by weight of water, of the total additive weight.
[0028] Microcapsules comprised of a cationic coating with a percentage weight, with respect to the total additive weight, of between 5% and 20%; and a nucleus of proliposomes, carnitine, escina, tetraethylammonium and/or caffeine, of between 1% to 10% by weight of the total additive weight.
EXAMPLE 4
Additive With Revitalizing, Anti-Wrinkle Cosmetic for the Skin
[0029] 80%-98% by weight of acidified water, with respect to the total additive weight.
[0030] Microcapsules with a cationic coating which constitutes between 1% and 5% by weight of the total additive weight; and a nucleus which comprises extract of Aloe Vera, and/or ubiquinone and/or retinol with a percentage weight, of the total additive weight, of 1% to 5%.
EXAMPLE 5
Additive With Anti-Stress Cosmetic
[0031] 80%-98% by weight of water of the total additive weight.
[0032] Microcapsules comprised of a cationic coating with a percentage weight of between 1% to 15%; and a nucleus which represents between 1% and 5% by weight of the total additive weight and which comprises extract of Kava ( Piper methysticum ) and/or serotonin.
[0033] Other examples of microencapsulated cosmetics products for administering as additives in the domestic clothes-washing process, are anti-wrinkle compounds, for example, collagenase inhibitors. These additives are specially designed to treat pillowcases.
[0034] Other additives according to the invention comprise whitening compounds or skin pigmentation inhibitors, or compounds to slow hair-growth, the latter being very suitable for washing tights which must be applied, for example, after a session of depilation. In all of these, the percentage weight of the microencapsulated product is between 1.0% and 40% of weight with respect to the total additive weight which is comprised, in addition to the microencapsulated product, of the cationic coating which surrounds the microcapsules and the liquid vehicle, such as acidified water.
[0035] Among the pharmacological products in the nucleus of microcapsules comprising the additive, bactericide or epulotic agents are also used, as are muscle relaxants. The latter are specially suited to clothing for people with muscle problems or pain.
EXAMPLE 6
Additive With Essence of Eucalyptus
[0036] 40%-85% by weight of water, with respect to the total weight of the additive for domestic washing processes.
[0037] Microcapsules with a cationic coating, with a percentage weight with respect to the total additive weight, of between 5% and 20%; and with a nucleus of 10% to 40% by weight of the total additive weight, of extract of eucalyptus.
[0038] This additive is preferably designed for the treatment, in domestic washing machines, of sheets and other bed linen to relieve cold symptoms.
EXAMPLE 7
Additive With Energy Properties
[0039] 80%-98% by weight of water (of the total additive weight).
[0040] Microcapsules with a cationic coating with a percentage weight, with respect to the total additive weight, of between 1% and 15%; and with a nucleus comprising essence of ginseng and moisturizers (extract of Aloe vera), with a percentage weight, with respect to the total additive weight, of between 1% and 5%.
EXAMPLE 8
Additive With Insect Repellent
[0041] 70%-94% by weight of water, of the total additive weight.
[0042] Microcapsules, with a mosquito repellent, of between 1% to 10% by weight of the total additive weight, and with a cationic coating of between 5% and 20% by weight.
[0043] In all the examples, the cationic microcapsule coating corresponds to any type of quaternized starch, of the type known by persons skilled in the art, e.g. leguminous plants, cereal starch, etc., such as maize, rice, tapioca, which are water-soluble. Fatty acids that have been modified to give them positive charges can also be used.
[0044] The additives in the examples 1 to 8 are usually, for example, for use with underwear, socks, tights, and even sheets.
[0045] All the cosmetic, pharmacological and evaporable products are used in the form of microcapsules with the fibres of garments that, once washed and rinsed, are subjected to the action of the additive according to the invention. Once dry, the garments retain the microcapsules, with the products of interest inside them, so that, by the effect of rubbing against the skin or movement of the user, the microcapsules break and the product inside is released.
[0046] The additive object of the invention is intended for insertion in the compartment used for additives for treating clothes, once washed and rinsed, where fabric softeners are generally added. The advantage of this additive is that the user can use it separately from the fabric softener to give the clothing the desired finish. Additives according to Examples 1 to 5 can thus be used when one is seeking a continuous, long-lasting application of a certain cosmetic with the clothing that is used by the user, e.g. a moisturizer for the legs which is released while the user is wearing tights which, beforehand, were treated for this purpose.
[0047] In other cases, the user can treat sheets so that a particular fragrance or essence is evaporated on a continuous basis.
[0048] In addition, during the domestic treatment process, various additives can be applied to the garments at the same time, for example, an additive with microcapsules with a moisturizing product and an additive with microcapsules with a photoprotective product. For this, the formulation of the additive in a single-dose is sufficient for the user to make up the desired combination as required.
[0049] The additive object of the invention is designed so that it adheres between clothing fibres at the working temperatures and speeds of domestic washing machines. Additives with microcapsules can thus be used up to 60° C. without compromising their consistency and, at the same time, favouring their impregnation into the fibres. Once the additive has been applied, the garment can be dried or ironed up to a temperature range of between 140° C. and 150° C. Once the user has worn the garment treated with the additive object of the invention, it is recommended not to wash it at more than 30° C. to prolong the effect, which does not generally run out until after 4 or 5 washes.
[0050] Obviously, the additive can also be applied in cases where hand-washing of garments is preferred. In this latter case, in order to ensure that the microcapsules are incorporated uniformly and to achieve high performance (impregnation of the fibres with a higher number of microcapsules), it is recommended to leave the garment treated in the additive for at least 10 to 15 minutes, stirring from time to time.
[0051] The additive for domestic washing processes, in addition to using an additive with a formulation that is not complex, leads to positive results deriving not solely from the cosmetic or pharmacological effect it has, but also in terms of its long-lasting effect. In this way, it should be highlighted that, with a treatment of this type, the garments manage to exert the desired effect, whether they are moisturizing or photoprotective products, an insecticide, painkiller, etc., at least for four washes without subsequent treatment with additives.
[0052] The additive for domestic washing processes, object of the invention, may be added in the form of a fine powder, the microcapsules having a granular size of between 5 μm and 15 μm, which is also the size of the microcapsules when they are applied in suspension in a liquid vehicle. Once the clothing has been washed and rinsed, the same water that enters the washing-machine compartment used to put all additives for special treatment of garments, is responsible for incorporating the powder particles or microcapsules therein, making up the liquid medium that will come into contact with the fibres. This allows for a more uniform distribution of the additive in all the clothes.
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Additive for domestic washing processes, for incorporation in the process after washing and rinsing, which is comprised of a microencapsulated product which is either a cosmetic, a pharmacological drug, or an evaporable product, the microcapsule coating being comprised of a cationic compound. The additive is preferably in the form of a liquid and in unit doses. The invention also relates to a process for treating fibres with the additive.
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BACKGROUND OF INVENTION
1. Field of the Invention
This invention concerns a safety relief for relieving the pressure of a gas within a pressure vessel such as an air compressor tank, a pressure tank used in manufacturing or a storage tank used to hold a quantity of gas under pressure.
2. Description of the Related Art
Pressure vessels are used in a wide variety of commercial, industrial and residential applications. For example, pressure vessels are often an important element in power and manufacturing plants. In such settings, pressure vessels provide a structural container for many possible functions including chemical reactions, treating, mixing and blending, separation, heat exchange and regeneration.
Pressure vessels are also used for the storage of a gas under pressure. Common examples of such vessels include cylindrical, barrel-shaped or drum-shaped containers for acetylene, propane, hydrogen, oxygen and carbon dioxide. Typically, gas storage vessels have wall sections that are relatively thick to withstand considerable pressure so that a relatively large amount of gas can be retained within the vessel. Gas storage pressure vessels are useful in many industrial, commercial, farming and residential applications.
Another well-known example of a pressure vessel includes the tank commonly used in connection with air compressors. The tank provides a reservoir for the temporary storage of compressed air so that the air compressor need not operate every time that a relatively small amount of air is withdrawn from the tank. The tank extends the useful life of the air compressor by reducing the number of times that the air compressor would otherwise be energized during intermittent withdrawal of pressurized air over a period of time.
Unfortunately, the energy stored in pressurized gases contained in pressure vessels represents a potential hazard that in certain circumstances can cause serious bodily harm and even death. If, for example, the vessel was manufactured with a welded seam that was relatively weak, the seam might rupture during use, and the force of the escaping gas might cause a fragment of the vessel to injure the operator or a bystander. Moreover, if the stored gas is flammable, the gas could ignite and cause a fire or explosion.
As a consequence, manufacturers of pressure vessels have devoted considerable attention over the years to the construction of vessels that are intended to safely contain gases under certain, pre-designated pressures. In addition, many states and cities of the United States and certain provinces and territories of Canada have adopted all or part of the A.S.M.E. Boiler and Pressure Vessel Code as a legal basis for pressure vessel construction. The A.S.M.E. Boiler and Pressure Vessel Code sets out certain minimum, essential construction requirements for pressure vessels in an effort to ensure that such vessels do not rupture when properly used as intended and correctly maintained.
Pressure relief valves are often used with certain vessels to keep pressure within the vessel below a certain specified limit. As an example, some tanks used in industrial processes to enclose and contain a chemical reaction are provided with a valve that opens to relieve pressure within the tank if the pressure exceeds the specified amount. The relief valve is useful for keeping pressure within the tank below the amount that is considered the maximum for safe operation as may be determined by the manufacturer of the tank.
However, some pressure vessels such as those made of steel may weaken after an extended period of time due to corrosion on an inner surface of the vessel wall. The corrosion may eventually weaken the wall to such an extent that the wall eventually ruptures when the vessel is in use. Such internal corrosion is especially hazardous because the visible, outer surface of the wall may appear relatively unblemished and lead the user to believe that the vessel is in satisfactory condition. As a result, the wall may rupture even though the pressure within the vessel is below the maximum rated pressure of the vessel as was originally determined by the vessel manufacturer.
It is known, for example, that the internal walls of air compressor tanks can corrode due to water vapor that condenses from compressed air in the tanks. Many manufacturers of air compressors attempt to avoid problems of internal corrosion by including a drain valve near the bottom of the tank. Instructions provided with the air compressor direct the user to open the drain valve after each use in order to drain condensed moisture from the tank.
However, the drain valves provided on air compressor tanks have not completely avoided the problems caused by moisture condensing within the tanks, and serious injuries due to rupturing walls of corroded tanks have still been reported. In some instances, the user may not read or fully comprehend the manufacturer's instructions to open the drain valve after each use. In other instances, the user may simply forget to open the drain valve. Many air compressor systems intended for household use maintain pressures of up to 125 p.s.i. or more, which is sufficient to cause significant injury if the tank were to unintentionally rupture.
There is clearly a need in the art to solve the problem of providing a safe pressure vessel in order to avoid personal injury and property damage that might otherwise occur due to internal corrosion of the vessel. Preferably, such a solution should be relatively inexpensive, adaptable to a variety of different vessels and yet require little, if any, attention from the user.
SUMMARY OF THE INVENTION
My present invention is directed toward a pressure vessel that includes a tank having wall sections defining a chamber. The wall sections include a bottom wall section having a certain average wall thickness. The bottom wall section also has at least one recess, and each recess presents a relief area in the bottom wall section that has a thickness less than the average wall thickness of the bottom wall section.
The relief area is located in the bottom wall section because moisture condensing within the chamber normally descends to the inner surface of the bottom wall section. The relief area provides a defined area of weakness in the tank wall sections that will rupture once corrosion in the bottom wall section in locations next to the relief area has advanced to such a degree that the relief area can no longer withstand the pressure of gas within the tank. Once opened, the relief area provides a vent to safely discharge the contained gas to the atmosphere and hinder further use of the tank.
In preferred embodiments of the invention, the recess extends upwardly from the outer surface of the lowermost portion of the bottom wall section, and narrows in cross-sectional area as the inner surface of the bottom wall section is approached. As one example, the recess has a shape similar to an inverted cone. Once corrosion inside the tank has progressed sufficiently to a degree to enable gas to escape through the recess, the relatively narrow cross-sectional area at the top of the recess functions as a whistle to signal the user that the tank is leaking and should be replaced.
These and other aspects of the invention are further described in the detailed description that follows as well as in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an exemplary pressure vessel constructed in accordance with one embodiment of my invention, wherein the pressure vessel in this instance includes an air compressor tank;
FIG. 2 is a bottom view of the pressure vessel shown in FIG. 1 which includes, for purposes of explanation and illustration, three recesses each providing a pressure relief area according to the invention; and
FIG. 3 is an enlarged, fragmentary cross-sectional view taken along lines 3--3 of FIG. 2 and showing one of the pressure relief areas that is constructed in a bottom wall section of the tank.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A pressure vessel 10 according to one embodiment of the invention is shown in FIGS. 1-3 and comprises in this instance an air compressor system having a tank 12. The air compressor system also includes an electric motor 14 (see FIG. 1) that is connected by a covered belt drive 16 to a compressor 18 (the belt and the pulleys of the belt drive 16 are not shown). The compressor 18 is coupled by tubing to the tank 12. The motor 14 and the compressor 18 are supported by a platform 19 that is secured to the top of the tank 12.
The air compressor system has a control mechanism 20 that is similar to control mechanisms well known in the art. The control mechanism 20 senses pressure in the tank 12, and initiates operation of the electric motor 14 whenever the pressure of compressed air in the tank 12 falls below a pre-selected minimum value. When the electric motor 14 is energized, the motor 14 drives the belt drive 16 which, in turn, drives the compressor 18 to direct pressurized air into the tank 12. The control mechanism 20 interrupts operation of the electric motor 14 once the pressure of compressed air in the tank 12 rises above a certain value.
The tank 12 has wall sections defining an enclosed, generally cylindrical chamber 22 (see FIG. 3). The wall sections include a bottom wall section 24, two side wall sections, a top wall section and two circular end wall sections. As one option, the tank 12 is made by rolling a sheet of steel into a cylindrical shape and welding along the seam to form the bottom wall section 24, the side wall sections and the top wall section. The end wall sections are then welded to the cylindrical shape of the other wall sections.
At least one support is connected to the tank 12 for supporting the tank 12 in an orientation wherein the bottom wall section 24 faces downwardly and extends across the bottom of the chamber 22 In the embodiment shown in the drawings, two supports in the nature of wheels 26 are connected to the side wall sections of the tank 12 near one of the end wall sections. In addition, a support in the nature of a stationary leg 28 spans the bottom of the tank 12 and is fixed to both of the side wall sections of the tank 12 near the other end wall section.
The air compressor system also has a handle 29 (FIG. 1) that is coupled to the platform 19. The handle 29 and the wheels 26 enable the air compressor system to be moved about as needed. However, once the system is moved to a desired location, the wheels 26 and the leg 28 support the tank 12 in a certain, consistent, horizontally-extending orientation wherein the bottom wall section 24 faces downwardly and extends across the bottom of the chamber 22.
As illustrated in FIGS. 2 and 3, the bottom wall section 24 includes three recesses 30 that extend upwardly from the outer, lowermost surface of the bottom wall section 24, although a fewer or greater number of recesses is also possible and within the scope of the invention. Preferably, each recess 30 has a horizontal cross-sectional area that decreases as the chamber 22 is approached. In the embodiment shown, each recess 30 has the shape of an inverted, truncated cone that terminates in an uppermost, pointed tip.
In many air compressor systems, the thickness of the tank wall is about 0.070 to 0.080 inch thick. A suitable recess may be constructed in such a tank wall by using a conventional metal drill bit having a diameter of about 0.035 to 0.040 inch, and drilling into the tank wall a distance equal to about one-half the thickness of the tank wall. The pointed end of such drill bits provides a suitable conical shape for the recess.
Each recess 30 presents an overlying relief area 32 in the bottom wall section 24. The thickness of the bottom wall section 24 in the relief areas 32 above the corresponding recess 30 is less than the average thickness of remaining areas of the bottom wall section 24. As an example according to the construction set out in the preceding paragraph, the thickness of the bottom wall section 24 in the relief area 32 is about one-half of the average thickness of remaining areas of the bottom wall section 24.
Finally, a drain valve 34 is provided in the bottom wall section 24 near one of the end wall sections. Once use of the air compressor system has been completed, the drain valve 34 is opened to drain any water from the chamber 22 that may have condensed out of the compressed air and collected in the tank 12.
Each pressure relief area 32 provides a weakened portion of the bottom wall section 24 that ruptures once significant corrosion has occurred on the inner surface of the bottom wall section 24. Corrosion may occur, for example, by the failure of the user to open the drain valve 34 and drain the condensate after each use of the air compressor system. As corrosion accumulates along the inner, upper surface of the bottom wall section 24 including the portions within the pressure relief areas 32, the strength of the bottom wall section 24 is gradually reduced until such time as the bottom wall section 24 is sufficiently weak to rupture within one or more of the relief areas 32 under pressures reached within the tank 12 during normal operating conditions.
Once one or more of the relief areas 32 is ruptured, pressurized air within the tank 12 is vented to the atmosphere. Advantageously, as the pressurized air escapes through the narrowed, pointed upper end portion of the recess 30 below the ruptured relief area 32, the fast-moving air escaping through the relatively small opening creates a high-pitched whistling sound. The whistling sound functions as an alarm to alert the user that significant corrosion within the tank 12 has occurred and that the tank 12 should now be replaced. Labels are placed on the tank 12 to instruct that user that the recesses 30 next to the ruptured relief area 32 should not be plugged, so that the relief areas 32 function as intended.
The relief areas 32 are located along the bottom of the inner surface of the bottom wall section 24 where the most severe effects of corrosion are expected to occur. As shown in FIG. 2, one recess 30 (and thus one relief area 32) is located at the center of the bottom wall section 24 in a direction lengthwise of the tank 12, while the other recesses 30 (along with their respective relief areas 32) are placed along the longitudinal bottom axis at a location that is nearer to the corresponding end wall section than the distance to the center recess 30. Other locations are possible as well.
It can be appreciated by those skilled in the art that many modifications and additions to the embodiment described above in detail can be constructed without departing from the spirit of my invention. For example, the pressure relief areas 32 could have shapes other than the shape of an inverted cone. The pressure relief areas could also be constructed by providing lines of weakness surrounding a circular, rectangular or other defined portion of the bottom wall section 24 that is intended to rupture under pressure and open outwardly as a panel after sufficient corrosion within the tank has occurred.
Moreover, the invention is useful for other types of pressure vessels in addition to the vessel shown in the drawings. For example, the pressure relief areas may be provided on bottom wall sections of tanks used with other types of air compressors systems such as larger air compressor systems having an upright cylindrical tank. Pressure relief areas may also be provided on other pressure vessels such as vessels used for storage of gases or for containing a chemical reaction or process.
Accordingly, the invention should not be deemed limited to the specific examples described in detail above and shown in the drawings, but instead only by a fair scope of the claims that follow along with their equivalents.
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A pressure vessel safety relief includes one or more recesses on a bottom wall section of the vessel. The thickness of the bottom wall section in areas directly over each recess is less than the thickness of remaining areas of the bottom wall section. Once the bottom wall section has corroded to a significant degree, the wall section ruptures in areas over the recesses to safely relieve pressure within the vessel. Preferably, the recess decreases in cross-sectional area as the top of the recess is approached, such that the escaping air emits a high-pitched whistling noise that functions as an alarm to notify the user that the vessel is corroded and should be replaced.
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FIELD OF THE INVENTION
The invention relates to portable devices for first aid, grooming and/or dental care.
BROAD DESCRIPTION OF THE INVENTION
An object of the invention is to provide portable devices which combine at least two capabilities of first aid, grooming, dental care and the like. Other objects and advantages of the invention are set out herein or are obvious herefrom to one ordinarily skilled in the art.
The objects and advantages of the invention are achieved by the devices of the invention.
The invention involves a portable device for dental care and grooming which includes an elongated member which has a passageway therein extending essentially the entire length thereof. The first end of the passageway is open and the second end is closed. A flashlight device is positioned in the passageway. The light bulb of the flashlight is located in the first end of the passageway. A toothbrush or other utilitarian device is removably attached to the end of the elongated member opposite of the end thereof containing the light bulb. There is an elongated cover which has a passageway therein extending all or most of the entire length thereof. The cover fits over the toothbrush and detachably onto the end of the elongated member. The first end of the passageway is open and the second end is closed. Preferably the elongated cover contains at least one hole therein near the toothbrush when the elongated cover is affixed onto the elongated member. Also preferably a magnifying glass is mounted on the end of the elongated member having the light bulb. Preferably the elongated cover contains in the second end thereof a chamber in which the magnifying glass is stored. The chamber preferably contains a cap on its second end.
The invention involves a portable device having a pen and for grooming, first aid or the like which includes an elongated member which has a passageway therein extending essentially the entire length thereof. The first end of the passageway is open and the second end is closed. An ink pen device is positioned in the passageway. The ink-writing tip or point of the pen is located in the first end of the passageway and is extendable into and out of the first end of the passageway. A first aid, grooming or other utilitarian device removably attached to the end of the elongated member opposite of the end thereof containing the pen tip. There is an elongated cover which has a passageway therein extending all or most of the entire length thereof. The cover fits over the first aid or grooming device and detachably onto the end of the elongated member. The first end of the passageway is open and the second end is closed.
Preferably the elongated cover contains at least one hole therein near the affixed onto the elongated member. Also preferably the elongated cover contains in the second end thereof a chamber in which a finger nail clipper is mounted. The chamber preferably contains a cap.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevational view, partially cutaway, of the main body of the portable device of the invention for dental care and grooming;
FIG. 2 is a side elevational view of the detachable cover of the portable device of FIG. 1;
FIG. 3 is a partial side elevational view of one version of the device of FIG. 1;
FIG. 4 is a partial view of an alternative way of detachably mounting the attachment of the device of FIG. 1;
FIG. 5 is a front elevational view of the magnifying glass used with the device of FIG. 1;
FIG. 6 is a cross-sectional side view of the magnifying glass mounted on the device of FIG. 1 (partially shown);
FIG. 7 is a cross-sectional view of the cap used on the cover of the device of FIG. 1;
FIG. 8 is a side elevational view, partially cutaway, of the magnifying glass stored in the top compartment of the cover of the device of FIG. 1;
FIG. 9 is a side elevational view of the assembled portable device of FIGS. 1 and 2;
FIG. 10 is a side elevational view, partially cutaway, of the main body of the portable device of the invention having a pen and an attachment;
FIG. 11 is a side elevational view of the detachable cover of the portable device of FIG. 10;
FIG. 12 is a side elevational view, partially cutaway, of the nail clipper located in the cover of the device of FIG. 10;
FIG. 13 is a cross-sectional view of the cap used on the cover of the device of FIG. 10;
FIG. 14 is a side elevational view of the assembled portable device of FIGS. 10 and 11;
FIG. 15 is a side elevational view of a razor attachment for the device of FIG. 10;
FIG. 16 is a side elevational view of a lip stick attachment for the device of FIG. 10;
FIG. 17 is a side elevational view of a lighter attachment for the device of FIG. 10; and
FIG. 18 is a market fit for attachments for the invention devices.
DETAILED DESCRIPTION OF THE INVENTION
Portable device 100 contains main body 102 (shown in FIG. 1) and detachable cover 104 (shown in FIG. 2). Main casing 106 is hollow (having passageway 108) and has bullet-shaped nose 110 with aperture 112 therein. Pen light bulb (flashlight bulb) 114 protrudes through aperture 112. Rubber nipples 116 hold flashlight battery 118 in chamber 108 in a tight but movable manner. Each bank of nipples 116 usually has three or four nipples 116 spaced equally in distance around chamber 108. Nipples 116 can be hard or resilient, but preferably are resilient. Cap portion 120 contains lower hollow portion 122, which is externally threaded. The other end (124) of main casing 106 is internally threaded. The bottom of battery 118 contacts nipple 126, which is constructed of an electrically conductive metal, such as steel, copper or aluminum. Nipple 126 is positioned on inner face 128 of cap portion 120 and is the end of wire or flat sheet 130. Flat sheet 130 is contructed of an electrically conductive metal, such as steel, aluminium or copper. Flat sheet 130 is L-shaped and fits in L-shaped passageway 132 of cap portion 120. Side wall 134 of cap portion 120 is lower than the outside of end 124 of casing 106. End 136 of flat sheet 130 extends radially outwardly out of passageway 132 about as far as end 124 of casing 106. Casing 106 is contructed of a conductive metal, such as steel, aluminum or copper. Top 138 of battery contacts the bottom of light bulb 114.
Toothbrush 140 contains arm 142 and bristles 144, which are preferably nylon. Threaded portion 146 on the end of arm 142 threadingly engages internally threaded passageway 148 in arm 150 of cap portion 120. Arm 150 (in FIG. 1) is located at the outer perimeter of cap portion 120. FIG. 3 shows another embodiment of the toothbrush arrangement, although the toothbrush arrangement in FIG. 1 is preferred. In FIG. 3, cap portion 152 has arm 154 which is located on the central axis of main body 102. Toothbrush 156 contains arm 158 and bristles 160. Arm 158 has outer arm portion 164, which is aligned with the outer perimeter of cap portion 152, curved arm portion 166 and inner arm portion 168. Threaded portion 170 on the end of the inner arm portion 168 threadingly engages internally threaded passageway 172 in arm 152 of cap portion 152.
Another method of attaching toothbrush 140 to cap portion 120 is shown in FIG. 4. Arm 148 of cap portion 120 contains passageway 174, which has small depression 176 located on the wall thereof. Short arm 178 of arm 142 of toothbrush 140 fits into passageway 174 in a tight but removable manner. Small nipple 180 on short arm 178 matingly engages depression 176 so as to assist in detachably affixing toothbrush 120 to cap portion 140. Passageway 174 and short arm 178 can have any matching cross-section, such as circular, triangular, square, etc. Depression 176 and nipple 180 are not required to keep toothbrush 140 from turning in relation to cap portion 120 as long as the cross-sections of passageway 176 and short arm 178 are not circular. Preferably passageway 174 and short arm 178 are both triangular in cross-section, are tightly fit and do not contain depression 176 and nipple 180, respectively.
Referring to FIG. 2, detachable cover 104 has casing 182, which is hollow (having passageway 184 therein). The bottom end of casing 182 has aperture 186. Passageway 184 ends at wall 188--see FIG. 8. Wall 188 forms chamber 190 which opens through aperture 192.
Shell 182 is constructed of an electrically conductive metal, such as steel, aluminum or copper. Pin 204 is mounted on the inside of shell 182 and is constructed of an electrically conductive metal, such as steel, aluminum or copper. When cover 104 is in place on main body as shown in FIG. 9, cover 104 can be turned to contact end 136 of flat sheet 130 which provides an electrical circuit that lights light bulb 114. Lightbulb 114 can be turned off by turning cover 104 to break the contact between pin 204 and end 136. Markings on the outside of cover 104 and shell 106 can be used to help align pin 204 and 136 in a close proximity.
Magnifying glass device 214 has magnifying glass 216 mounted in slot 218 on the back area of the inner surface of rim 220. The lower end of magnifying glass 216 has removed--see FIGS. 5 and 6. The lower side of rim 220 has concave portion 222 so that magnifying glass device 214 stably fits on the top of shell 106 as shown in FIGS. 1 and 6. Spring clip 224 is affixed on the top, front portion of shell 106 as shown in FIG. 1. The free end of spring clip 224 fits into and through C-loop member 226 as shown in FIG. 6. The mounting of clip member 226 in the bottom inside of rim 220 is best seen in FIG. 5.
When magnifying glass device 214 is mounted on the front of main body 102, light 114 and magnifying glass device 214 can be used to examine the teeth of a person or, with the aid of a mirror, to examine one's own teeth.
End cap 228 fits tightly, but detachably, on the end of main body 104 away from light bulb 114. Protrusion 230 is located on the inside of cap 228 near its lower rim. The end of casing 182 which contains depression 234 around its outer side. When cap 228 is placed on the end of casing 182, protrusion 230 fits in depression 232.
As shown in FIGS. 1 and 2, main body 102 (i.e., casing 106 and cap 120) and detachable cover or cap 104 have a circular cross-section, but can have any cross-section, such as hexagonal, square, octagonal or oblong.
Unless otherwise stated herein or obvious herefrom, the various parts of the invention embodiments can be constructed of any suitable material, such as plastic or metal or of any material(s) conventionally used for such part(s).
Portable device 300 contains main body 302 (shown in FIG. 10) and detachable cover 304 (shown in FIG. 11). Main casing 306 is hollow (having passageway 308) and has bullet-shaped nose 310 with aperture 312 therein. Pen tips 314 of ball point pen 316 protrudes through aperture 312. Ball point pen also has ink-reservoir 318, which is located in chamber 308. Cap portion 320 contains lower hollow portion 322, which is externally threaded. The other end (324) of main casing 306 is internally threaded. The upper end of ink-reservoir fits, without too much clearance, in chamber 326 in lower portion 322 of cap portion 320. Coil spring 328 is located in the front end of chamber around pen tip shaft 330. Coil spring 328 keeps the end of ink-reservoir 318 firmly against the top of chamber 326. When cap portion 320 is screwed in or out of end portion 324 of main body 302, the end of ink-reservoir 318 slides on the top of chamber 326 so as not to cause any significant twisting of coil spring 328 or rotation of ink pen 316. Cap portion contains expanded or head portion 328, which has two diametrically-positioned vertical grooves 330 with expanded V-shaped throats. Most of the parts of main body 302, such as casing 306 and cap portion 320, are preferably constructed of a durable, break-resistant plastic but can be made of any suitable material, such as one of the metals.
Clothing or utility brush 332 contains arm 334 and bristles 336. Hole 338 is located in head portion 428, preferably is triangular in shape but can have any cross-section, such as circular, rectangular or square. Hole 338 may contain a small depression in the wall thereof. The inner arm portion of brush arm 334 has short arm 340 that fits into hole 338 in head portion 428. Short arm 340 preferably is triangular in shape but can have any cross-section, such as circular, rectangular or square. Short arm 340 can have a small nipple thereon which matingly engages such depression so as to assist in detachably affixing brush 332 to head portion 428. Such depression and nipple are not required to keep brush 332 from turning in relation to cap portion 320 as long as the cross-sections of hole 338 and short arm 340 are not circular. While not preferred, short arm 340 can be circular and externally threaded and hole 338 can be circular and internally threaded. When a screw-in arrangement is used, the parts need to be machined or formed with precision or a stop has to be placed on the short arm 340 in hole 338 to insure that brush 332 is not out of line with main body 302.
Referring to FIG. 11, detachable cover 304 has casing 342, which is hollow (having passageway 344 therein). The bottom end of casing 342 has aperture 346. Passageway 344 ends at relatively thick wall 348--see FIG. 12. Wall 348 forms chamber 350 which opens through aperture 352. Nail clipper 354 includes curved, spring arms 356 and 358, which end in blades 360 and 362, respectively. Blades 360 and 362 are concave on the horizontal plane. The other end of blades 360 and 362 are affixed on wall 348, which is constructed of metal or other material of equal strength to support the stress caused by the use of nail clipper 354. Vertical pin 362 fits through a hole in arm 358, a hole in arm 356 and a hole in arm in the top of casing 342. Cap 366 is attached to the bottom of pin 362 shown in FIG. 12. The upper end of pin 362 contains slot 368 which is shaped like a hook. Curved arm 370 has hole 372 (see FIG. 12) which allows the end of arm 370 to pivot in the top of slot 368 from the rest position (see FIG. 11) to the lever position (see FIG. 12). When in the lever position, pressure on the end of arm 370 causes blade 362 of arm 358 to be moved towards and contact blade 362 of arm 358 (so as to cut a finger or toe nail). Pin 426 helps prevent the upward deformation or movement of arm 356.
End cap 374 fits tightly, but detachably on the end of main body 302 away from pen tip 314. End cap is deep enough so that the ends of arms 356 and 358 do not contact it. Protrusion 376 is located on the outside of the lower rim 378 of cap 374. Lower rim 378 is diminished in diameter from main rim 380 of cap 374. Flat hole 382 in main rim 380 is used to remove end cap 374 from cover 304. The end of casing 342 contains depression 384 arount it inner side. When cap 374 is placed on the end of casing 342, protrusion 376 fits in depression 384.
Any number of slots 330 (see FIGS. 15 to 17) can be used. A corresponding number of nipples 386 are located on the inside of the lower portion of shell 342 of cover 304. Nipples 386 fit into slots 330 when cover 304 is placed on main body 302 (enclosing brush 332). Referring to FIGS. 10 and 14, when cover 304 is in place, it can be turned to cause ballpoint pen tip 314 to move in or out of aperture 312. Marks on the outside of cover 304 and main body 302 can be used to assist in aligning nipples 386 with slots 330.
As shown in FIGS. 10 and 11, main body 302 (i.e., casing 306 and cap 320) and detachable cover or cap 304 have a circular cross-section, but can have any cross-section, such as hexagonal, square, octagonal or oblong.
FIG. 15 shows razor attachment 426 for detachable mounting in cap portion 320 by means of short arm 388 at the end of arm 390. Conventional double bladed razor head 392 is pivotally mounted on the end portion of arm 390 by means of pivot 394. Numeral 396 indicates the two razor blades. Razor head 392 is shown in the storage position in FIG. 15, but in use it is pivoted 90 degrees clockwise to be in the shaving position. Pivot means has lock positions at the storage and use positions.
FIG. 16 shows lip stick attachment 398 for detachable mounting in cap portion 320 by means of short arm 400. Container 404 can be a conventional lip stick container which is capable of accepting replacement sticks of lip stick or the like. Container 404 includes bottom casing 406, turning grip 408, inner casing 410 and lip stick 412.
FIG. 17 shows lighter attachment 414 for detachable mounting in cap 320 by means of short arm 416 mounted on the bottom of lighter 418. Lighter 418 is a conventional cigarette lighter having casing 420, pivotal top 422 and a file-movement spark producing element, the handle (422) of which is shown. The handle (424) is used to move the file by thumb action.
The changeable brush 140 is small, fine and soft, and is made of nylon bristles which are set in rows to get in between the teeth and way back in the mouth.
Device 300 shown in FIG. 15 is for men, having a razor and a ball pen which is driven in and out by twisting the cap. The razor blade can be a changeable GII blade. FIG. 16 shows device 300 for women, having a tube of lip stick and a ball pen which is driven in and out by twisting the cap. The tube of lip stick is also changeable or of the refill type. Brush 332 can be replaced by a comb, so then device 300 would be for children, having a comb and a ball pen. The comb is also changeable.
The invention device does not diminish the function of a pen set since it still has a ball pen to write with when the necessity arrises. The invention device has simply added a few conveniences and advantages in a vital limited space.
One can clean one's smile, teeth and mouth the natural way with the invention groomer and water from the facet wherever one is located. One can rinse and brush one's teeth to remove residue foods in particularly sugary foods to limit exposure after each meal, for esthetic of the smile, to guard against unpleasant mouth odors, to massage and strengthen the connective gum tissues which holds the teeth and to help prevent infectious diseases. The invention groomer automatically eliminates the need for dental toothpaste which normally contain abrasives, additives, preservatives, artificial coloring and artificial flavoring which are supposedly detremental to one's health when absorbed. To file down the enamel of one's teeth by hard brushing is not recommended nor is it necessary wherever one is at the time.
FIG. 18 shows a marketing kit which can be used with the invention devices, being sold in places, such as natural food stores and drug stores. The kit can be tailored in content for men, women or children. The kit allows the user to always have a spare item. The kit could contain a replacement toothbrush, razor, Vick's inhaler, retractable glue sticker, toothpaste tube, sewing spindel (and needles), comb, lighter and replacement sticks, such as lip stick, Aloe vera stick, septic stick, First Aid stick and wax stick, for use in the lip stick attachment. The Aloe Vera stick could be in a soft form.
The invention groomer helps insure and facilitate the cleaning of the mouth, the teeth and the smile after each meal. It helps eliminate the need for dental toothpaste which normally contain abrasives, additives, preservatives, artificial coloring and artificial flavoring which are supposedly detremental to your health when absorbed. By providing one's body with the necessary nutrients and by eliminating the elements which diminish good general health, one can help one's defense mechanism to prevent diseases of the mouth, the gums, the teeth and the body since many things including digestion start in the mouth. There is a savings in pain, tooth decay, dental work, and work stoppage.
The invention groomer, having the likeness of a pen set, comes in sets for men, women and children. The primary function of the groomer is to clean the mouth and the teeth in order to prevent diseases of the mouth, the gums, the teeth and the body. Another embodiment conveniently assembles a razor, lip stick, nail clipper, comb, pen light, cigarette lighter and ball pen to accommodate men and women, young or old. For men, the invention groomer can be equipped with a toothbrush and a pen light. The second piece can have a razor, a ball pen and a nail clipper. For women, the invention groomer can be equipped with a toothbrush and pen light. The second piece can have a tube of lip stick, a ball pen and a nail clipper. For children, the invention groomer can have a toothbrush and a pen light. The second piece can have a comb, a ball pen and a nail clipper. The various tools are exposed by removing the respective caps which show the nail clipper at the end of the holding clamp of the second piece.
The invention groomer is a compact unit consisting of a toothbrush, a pen light, a magnifying lens, a razor, a tube of lip stick, a ball pen, a comb and/or a nail clipper, which can be housed several at a time in a set with the likeness of a pen set designed to serve men, women or children as applicable. The cigarette lighter which may be substituted in the second embodiment device for the razor, tube of lip stick or comb for smokers, as desired. In a dispenser mechanism similar to the tube of lip stick, a first aid refill, such as Aloe Vera, wax, glue, sewing kit, toothpaste, if desired and others may be substituted in any of the second embodiment devices as appropriate.
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Portable device for dental care and grooming which includes an elongated member which has a passageway therein extending essentially the entire length thereof, the first end of the passageway is open and the second end is closed. A flashlight arrangement is positioned in the passageway. The light bulb of the flashlight is located in the open end of the passageway. A toothbrush or other utilitarian device is removably attached to the end of the elongated member opposite of the end thereof containing the light bulb. There is an elongated cover which has a passageway therein extending all or most of the entire length thereof. The cover fits over the toothbrush and detachably onto the end of the elongated member. The first end of the passageway is open and the second end is closed.
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This application is a continuation-in-part of U.S. patent application 07/985,194, filed Dec. 3, 1992, now U.S. Pat. No. 5,329,656.
FIELD OF THE INVENTION
This invention relates to improved lightweight inflatable mattresses.
BACKGROUND OF THE INVENTION
Individuals typically require a comfortable surface, or mattress, on which to recline while sleeping or resting. In particular, individuals involved in activities such as camping and backpacking need a mattress which is portable, lightweight, puncture resistant, inflatable or self-inflatable, insulating, and comfortable. Smaller units may be used as pillows. Further, lightweight portable mattresses find use in many other areas.
Mattresses intended for camping and backpacking have used a number of approaches to obtain these properties. They include: a) basic chambered air mattresses; b) simple thin resilient insulating pads; c) open-cell resilient foam pads (typically 1 to 2 inches thick); and d) a variety of insulated air mattresses.
Each of these approaches has been found deficient in one or more aspects. Basic chambered air mattresses provide very little insulating benefit and require an excessive amount of time and effort to inflate. Thin pads fabricated from natural resilient materials tend to be relatively heavy and provide very little cushioning benefit. Thin pads made from synthetic materials, such as closed-cell vinyl-nitrile (Ensolite), ethylene-vinyl acetate (EVA), or polyethylene foam, reduce weight but provide only a limited comfort benefit. Pads made from thermoformed closed-cell foams are described in U.S. Pat. No. 4,980,936 to Frickland et al. That patent also presents extensive background material on the use of foamed pads. Although closed-cell foam pads could be made thicker, this would increase weight and reduce portability.
Portable pads formed of resilient open-cell foam sheets, such as polyurethane are typically 1.0 to 2.5 inches thick. This resilience and increased thickness makes the pad somewhat more comfortable at the expense of increased weight and bulk.
Thereafter, inventors created several versions of insulated air mattresses. These designs completely or partially filled an air-impervious air mattress cover with resilient insulating materials. One such approach to providing a self-inflating foam filled air mattress is disclosed in U.S. Pat. No. 3,798,686. In this patent the resistance of the foam core to compression is utilized to give the air mattress its self-inflating characteristic. The foam core shown in this patent comprises upper and lower continuous sheets of open-celled foam, between which two layers of crossing foam ribs are configured. The foam components are all bonded to one another, and the entire structure is enclosed within a flexible cover, preferably of an air-impervious nylon type. The limited number of spaced 0.75 inch width rectangular foam ribs on 2.5 inch centers together with stress caused by low superatmospheric pressure, generates higher stress levels at the edge of the bonds than at areas towards the center of each bonding area. This unequal utilization of the ribs' tensile strength properties increases overall weight and the probability of bond delamination or rib tearing beginning at the rib edges and progressing towards the center of each bond. Compensatory measures such as increasing rib or bond strength leads to increased weight and/or costs. This design relies upon the upper and lower continuous sheets of open-cell foam for much of its insulating benefit. When rolled, the areas under the longitudinal (lengthwise) ribs are significantly bulkier than adjacent areas, leading to a greater than necessary overall rolled size.
U.S. Pat. No. 4,688,283 to Jacobson, et. al. discloses a multi-chambered mattress which utilizes an open-cell foam within a air-impervious nylon cover. The mattress is divided along its length into multiple chambers with differing thicknesses of foam. The significant quantity of open-cell foam materials together with the air-impervious cover leads to the weight penalty associated with both of the preceding designs.
U.S. Pat. Nos. 4,025,974 and 4,624,877 to Lea, et al. disclose a single chamber design which encloses a single slab of open-cell foam. The patentees laminate the top and bottom surfaces of an open-cell foam to the inside of a cover made of an air-impervious plastic-coated fabric. This foam-to-cover bond reduces displacement ("ballooning" or "billowing") of the covers and enables better pressure management. Billowing occurs when top and bottom covers are inadequately linked mechanically to each other and are free to expand from one another. Unless it is limited properly, this billowing creates an unstable surface and provides inconsistent support for the user. As with the other self-inflating insulated air-mattresses described above, the use of a solid insulating open-cell foam sheet and separate air-impervious cover components significantly increases mattress weight. Unless done with great care, perforation of the open-cell foam sheet to reduce weight may act to; a) reduce insulation; b) lead to destructive delamination between the foam sheet and the cover element where the remaining foam or bonding area is unable to sustain the load placed upon it; and c) diminish the mattress's horizontal dimensional rigidity. The insulation value of the open-cell foam sheet is critical since the cover does not provide significant insulating value. In U.S. Pat. No. 4,025,974 at Column 10, lines 14-19 and at Column 11, lines 40-47 it is stressed that it is necessary to bond the cover to the foam-sheet along substantially the entire horizontal surface because there is a tendency when a small area of non-bonding bonding or delamination occurs in an area where the skin is tensioned outwardly for this delamination to spread progressively, even under moderate pressure. Given the inflated profile of the cover and open-cell foam sheet when bonded together, perforation of the open-cell foam sheet of U.S. Pat. No. 4,025,974 would accelerate the delamination process. While the bond between the foam and cover could be strengthened through use of an improved adhesive, the necessity of bonding the entire foam surface to the cover could significantly increase cost and weight. Because of the flexible nature of the air-impervious cover, this design relies upon the open-cell foam sheet for the dimensional rigidity necessary for proper inflation. More recent designs have utilized foam sheets with transverse circular perforations or tubular voids running horizontally through the foam sheet. This approach leaves substantially continuous thin foam layers along all of the inside bottom and top mattress covers, inter-connected by foam material or ribs. The thin foam layer imparts the dimensional rigidity necessary to support the cover between adjacent ribs. The ribs are on approximately 2.75 inch centers and are approximately the same width as that of the longitudinal void spaces remaining between the horizontal tubular voids. While the ribs run in only one direction and the fabrication approach differs, this design shares common features with the previously referenced U.S. Pat. No. 3,798,686. The thin layers of foam left at the top and bottom of the foam sheet over the tubular voids increase the relative load bond area resisting delamination at the expense of increased fabrication complexity and expense. While increasing bond area, this approach makes inefficient use of the foam and fabric coating (or adhesive) tensile strength, focusing the greatest stress along the outer edges of each foam rib (and associated bond) and relatively lower stress towards the center of each foam rib.
As additional background information, other examples of foam filled structures are disclosed in the following patents: British Pat. No. 984,604; Brawner U.S. Pat. No. 1,159,166; Nappe U.S. Pat. No. 2,834,970; Lerman U.S. Pat. No. 3,323,151; Cornes U.S. Pat. No. 3,378,864; Kain U.S. Pat. No. 3,537,116; and Gottfried U.S. Pat. No. 3,611,455. In U.S. Pat. No. 4,092,750 a metallized film is used in the mattress's interior for added insulation.
Even with the use of tough coated synthetic fabrics, these mattresses are susceptible to punctures. A foreign object only has to penetrate between fabric strands to puncture the very thin polymer coating. Previous designs have focused upon the use of very thin materials, typically in the range of about 4 mils to about 15 mils. When such a mattress is punctured, air pressure is lost, and the mattress's support is reduced or lost completely.
Finally, the mattress's comfort is limited by the fully sealed nature of the mattress. This limits the mattress's ability to respond to changing conditions, such as switching from lying on one's back to lying on one's side. One example of an attempt to eliminate this limitation is presented in U.S. Pat. No. 4,328,083 to Lineback. This approach locates one or more resilient subchambers within the confines of the larger air mattress envelope. When force is applied to the air mattress, the enclosed fluid presses against the resilient subchambers. Being open to the atmosphere, these chambers deform, releasing air to the atmosphere, thereby partially releasing pressure within the primary chamber. The fixed resilience of these subchambers restrict the ability of the air mattress to respond to individuals with differing weights and to individual preferences.
The present invention overcomes the weight, comfort, and puncture problems associated with prior insulated air mattresses. Relatively thick air-impervious foamed material is used in place of at least one of the prior thin fabric or plastic sheet materials to provide at least one surface which generally is used as the bottom surface of the cover or enclosure. This approach enables one component to provide air-imperviousness, insulating, puncture resistance, and dimensional rigidity functions leading to an overall weight reduction. Weight is further reduced through the use of internal resilient material configurations which provide a high degree of void space. The corresponding decrease in bond area enables the use of stronger bonding agents to bond the resilient materials to the covers without an overall increase in cost. Optionally, bond strength is enhanced through the use of sculptured bonding surfaces to equalize tension across the bond. Optionally, mattress dimensional rigidity may be increased through the configuration of additional separately inflated chambers in the interior of the mattress. Optionally, comfort is enhanced by a configurable subchamber filled with resilient material configured such that the controlled release of internal mattress pressure is enabled when a force is applied to the mattress.
While the prior art has recognized the value of a wide range of design features, in the present invention those properties are utilized in combination and in select configurations to: a) reduce the stored volume of the internal resilient materials; b) maintain reliability as the quantity of resilient material is reduced; c) increase comfort across a broader range of mattress configurations; d) optimize the performance of the relatively thick air-impervious foamed material when used in self-inflating application; e) enhance self-inflation and largely self-inflating operation; and f) reduce overall weight.
SUMMARY OF THE INVENTION
Accordingly, several objects and advantages of my invention arise from a novel mattress construct which provides a mattress combining insulation, air-imperviousness, and structural integrity in one component. Associated refinements enable: enhanced self-inflation operation after storage; enhanced displacement control module/bond tensile strength management; reduced relative stored volume; enhanced comfort characteristics; and reduced weight. The present invention comprises an insulated mattress which is a substantially fluid-impervious inflatable enclosure, at least one broad surface or side of which is formed using a relatively thick insulating material, in particular a resilient semi-rigid closed-cell foam, having a closable means such as a valve or stopper for admitting to and releasing from the enclosure a fluid such as air, water, or the like which also permits varying the quantity of enclosed fluid. When the closable means is opened, air or other liquid is introduced to inflate the mattress. Closure maintains the mattress in the inflated mode. In a preferred embodiment the mattress contains sufficient compressible resilient units attached to the inner surfaces of the enclosure to cause the enclosure to self-inflate when a fluid is admitted to the enclosure and substantially reduce billowing of the enclosure under pressurized conditions.
In one embodiment, the relatively thick air-impervious cover material is modified to facilitate self-inflation. Modification techniques include, but are not limited to, replacement of selected cover elements with a thin air-impervious material and densification of selected areas of the cover material.
In another embodiment the invention provides a mattress which provides increased internal bond reliability by using the resilient materials in such a manner that the tensile properties of the resilient materials are more fully utilized. One approach pre-contours the bonding surfaces of the resilient inflation/displacement control modules and/or the insides of the covers. Selected embodiments provide module width and intermodule spacing such that simple uncontoured bonding surfaces bonds between the module and covers are sufficient to reliably resist tearing.
In another embodiment, the invention provides a mattress which has a smaller relative volume when stored by distributing the internal resilient materials in orientations such that the quantity of resilient material across the stored width of the mattress is roughly equalized thereby avoiding resilient material concentrations which would otherwise increase stored bulk. Another embodiment of the invention uses a mix of thin fabric or plastic sheet and resilient material-based control members to obtain the benefits of both. Another embodiment of the invention provides a mattress with increased user comfort and mattress reliability by providing a user configured pressure control chamber. Another embodiment of the invention provides a mattress which increases user comfort by providing a user configured lumbar support assembly. Another embodiment of the invention provides a mattress with vertically stacked independent air-impervious chambers. Another embodiment of the invention provides a mattress with improved self-inflation characteristics through inclusion of one or more small subchambers, with a fluid source independent of that for the main mattress chamber, structured in such a fashion as to cause the mattress cover to unroll and/or increase the cover's rigidity when a quantity of fluid less than that necessary to fully inflate the mattress is admitted to the subchamber(s). Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
DESCRIPTION OF THE FIGURES
FIG. 1a shows a cutaway view of the internal structure of a mattress of the invention.
FIG. 1b shows a cutaway view of the internal structure of a mattress which contains a number of inflation/displacement control modules.
FIG. 2 shows an optional edge reinforcement strip for the seams of the mattress of the invention.
FIGS. 3a and 3b show the profile of a mattress of the invention when inflated and show a number of alternative inflation and/or displacement control mechanism configurations.
FIGS. 4a, 4b, 4c, 4d, and 4e show a number of alternative optional shaped or contoured bonding surfaces which may be utilized on small spot, narrow elongated strip foam, perforated sheet, and formed/machined sheet inflation/displacement control module configurations.
FIG. 5 shows an optional pressure/comfort control assembly.
FIGS. 6a and 6b show alternative configurations which facilitate self-inflation.
FIG. 7 shows a mattress having an optional lightweight sheet or baffle enclosed within the mattress to further increase its insulating properties.
FIG. 8 shows a cutaway view of a mattress which contains a number of subchambers.
FIG. 9 shows an optional movable, adjustable resilient lumbar support pad with the mattress of the invention.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of the invention is illustrated in FIG. 1a. The mattress 11 consists of first (bottom) and second (top) cover elements or surfaces 1 and 2 having edge connections 5 to form a substantially fluid-impervious flexible enclosure. At least one of the top and bottom cover elements, usually the lower surface 1, is formed of a relatively thick, puncture resistant, air-impervious, resilient semi-rigid closed-cell foamed material. In a preferred form of the invention both covers 1 and 2 are made of such a material. The term "resilient semi-rigid closed-cell foam" as used herein means a semi-rigid closed-cell foam which has sufficient rigidity to be substantially self-supporting supporting between two support points and will withstand a 180° mandrel bend and substantially return to its original form. Appropriate cover materials include, but are not limited to, resilient semi-rigid closed-cell foams of polyethylene, ethylene-vinyl acetate (EVA), blends of ethylene polymers and/or copolymers, acrylic, PVC, polyurethane, natural or synthetic rubber and the like. Typically the thickness of the cover may range from about 1/16 inch or less to about 3/8 inch or more. Typically the densities of commercially available materials vary from about 1.2 to about 6 lb/ft 3 . Some are offered, and may be used, with high-friction or textured surfaces, skin-like surfaces, fiber reinforcement, or have been bonded to other plastic sheeting or fabrics. Commercial products such as Epilon® (Youngbo America) and Volara® (Voltek), cross-linked ethylene polymer foams having a density of about 2 lb/ft 3 bonded to various reinforcement or wear layers, have been found to be suitable for the purposes of the invention. The thickness of covers of the invention should be contrasted to typical covers of the prior art which range from about 4 to 15 mils thick. The increased thickness and the inherent toughness of the closed-cell foam cover or covers of the mattress of the present invention significantly improve the mattress's resistance to punctures, and provides enhanced insulating capabilities, while the semi-rigid nature of the cover imparts the horizontal dimensional rigidity required for dimensional stability of the mattress. The relatively thick air-impervious layer resists punctures even when foreign objects have partially penetrated the cover. A valve assembly, plug, cap, or equivalent closure 4 is used to enable the controlled exchange of fluid (air, water, etc) between the enclosed volume of the mattress and the atmosphere.
When the mattress is stored in a rolled form or folded for several hours, the closed-cell foam material may experience a "memory" effect. This characteristic slows the closed-cell foams return to its natural flat profile. This memory effect is greatest along the edges (when a single sheet is used to form top, bottom, and sides of the mattress) or along mattress folds.
Referring to FIG. 6a, the memory effect may be reduced and self-inflation facilitated by densifying the foam or substituting a thinner foam as shown at 40a and 40b, or substituting relatively thin air-impervious material for an entire side, usually the top 2, or may be limited to sides 8, or very narrow (about 1/8 inch) longitudinal strips 40a and/or 40b in the side walls 8. This creates a hinge effect between the top surfaces and side walls. Folding may be substituted for rolling to minimize the memory effect in those areas other than in the immediate area of the fold. Referring to FIG. 6b, one or more very narrow strips (about 1/8 inch) 41 along the expected fold line may be densified and/or replaced with another relatively thin air-impervious material on the surface which will be hidden after folding. This may also be applied one or more times on the opposite cover surface 42 in the area of the fold. This creates a hinge effect facilitating folding and unfolding. The mattress may be folded after manufacture to create this hinge effect utilizing the foam's memory. Typically a back and forth accordion fold may be used. Six to eight folds will yield a stored size of between about 9 inches and 12 inches for a 72 inch long mattress. Alternately the side walls may be thermoformed into the appropriate inflated profile. Each of the alternate configurations retain the beneficial characteristics obtained by utilizing the subject foamed air-impervious material as the bottom cover surface 1.
Referring to FIG. 8, self-inflation may also be facilitated by including at least one relatively small internal subchamber 43 in the enclosure structured in a manner to cause the mattress cover to unroll and/or increase the cover's dimensional rigidity when a quantity of fluid less than that necessary to fully inflate the mattress is admitted. These subchambers 43 may extend along the length of the mattress, inter-linked by one or more transverse subchambers 44. The subchamber may be provided with vertical protrusions 45 or may be wider in the vertical dimension 46 which act to cause the bottom 1 and top covers 2 to separate upon the admission of a relatively small quantity of fluid. The subchamber(s) 44 may be physically attached to the covers 1 and 2 or positioned between other internal mattress components to avoid undesired subchamber shifting. The size of subchambers and interchamber spacing will be affected by the intended application, available fluid pressure, the cover material being supported, and the degree of rigidity desired in the mattress. Inter-chamber spacing would be reduced for more flexible cover materials and for applications requiring greater rigidity or surface flatness.
In a preferred embodiment of the invention shown in FIG. 1b a mechanism 3 is provided to force the covers 1 and 2 apart and cause self-inflation of the mattress. In prior art constructions either a separate frame, or a substantially continuous internal surface pressing against the inside of the cover, has been required. Due to the semi-rigid (horizontal dimensional rigidity) nature of one or both of the covers 1 and 2, it is only necessary to apply force at discrete points throughout the interior surfaces 9 of the mattress to separate the covers 1 and 2 and cause self-inflation. Use of the previously described air subchambers 43 (FIG. 8) to increase dimensional rigidity for covers formed from flexible fabric or plastic sheets will enable increased separation between supports. A light weight material having a density in the range of about 0.8 to 1.8 pounds per cubic foot such as an open-cell foam (polyurethane or polyether foam, neoprene polymer foam, low density polyethylene foam, ethylene copolymer foam, polyisoprene sponges, or the like), springs, or bonded fibers is preferred.
Cover displacement is limited by mechanically linking the bottom and top covers 1 and 2. A number of configurations may be used to link the bottom and top covers 1 and 2. Several alternatives are shown in FIG. 3a. The preferred configuration combines cover displacement and self-inflation functions in a single inflation/displacement control module 3 made from any of the light-weight resilient materials described above and bonded to the interior sides 9 of the covers 1 and 2. When used as a combined inflation displacement control module, the material for the module is selected to provide sufficient tensile strength to restrain the covers for displacement control and sufficient resilience to have the compression and expansion properties necessary for the inflation functions. The elasticity of the inflation/displacement modules and several of the available cover materials enables the mattress volume to effectively increase in response to sudden pressure surges thereby reducing bond failures between the control modules 3 and the inside surfaces 9 of the covers. Typical maximum elongation values for open-celled polyurethane foams range from 125% to 250% of original thickness.
In another embodiment a flexible component 16 made of fabric or plastic sheeting may be used to limit/control separation of the covers 1 and 2. The displacement limiting components 16 are distributed throughout the interior of the mattress and thermally or adhesively bonded to the interior sides 9 of the bottom and top covers 1 and 2. The fabric or plastic sheeting component 16 may take the form of the I-beam shown in FIG. 3a or a simple [shape in which the top and bottom elements are bonded to the interior cover surfaces, or a single sheet 19 (FIG. 3b) alternately bonded to the interior of the top 2 and bottom 1 surfaces to form alternating upright and inverted V profiles, a circular tufted structure or a similar construction. The V profile 19 creates air breaks or barriers which reduce internal convection currents. In this approach, a separate resilient inflation component 15 (see FIG. 3a) or a subchamber 43 (see FIG. 8) is provided to force the two covers 1 and 2 apart. Alternately the self-inflation and displacement control mechanisms may be bonded to one another as illustrated by 17 (FIG. 3a). The displacement control mechanism may be wrapped completely around the self-inflating mechanism leaving space for the admission of fluid from the interior of the mattress. The displacement control mechanism 17 is then bonded to the interior sides 9 of the covers. A mix of resilient and fabric or plastic sheeting displacement limiting modules may be used to obtain the benefits of both.
Use of a preferred combined inflation/displacement control module 3 minimizes the number of components required to enable self-inflation and displacement control functions. The resilient modules 3 serve to first force apart and then maintain or stabilize the displacement between the two covers. FIGS. 4a-e present several expanded views of alternative individual resilient inflation/displacement control modules 3. While square and rectangular (in the horizontal dimension) modules 3 and cutouts 24 are represented, many shapes are appropriate including circular and oval, long straight or serpentine strips, and the like. The choices are limited only by the ingenuity of the designer. Displacement control module configurations which equalize stress across the entire module and bond cross-section increase reliability and reduce weight. Contoured bonding surfaces 21 of the modules 3 optionally may be used to equalize the stress across the entire bonding cross-section of the module. When this approach is used, the surface slope 21 is selected to match the wave profile of the inflated cover as shown in FIG. 3a. This stress equalization eliminates localized areas of excessive stress which might lead to bond edge peel and subsequent bond failure between the module 3 and the inside cover surface 9 or to tearing the module. Alternatively some or all of the contouring may be done to the bonding areas of the inside cover surface 9 rather than just to the module(s) 3. The contouring may be accomplished by means such as thermoforming, molding, surface machining and the like. FIG. 4c shows a contour 22 which may be used for locations where the displacement or separation between the upper and lower mattress surfaces is varied as in a contoured mattress. This contour equalizes stress across the displacement change region. FIG. 4d presents a construction utilizing a perforated resilient sheet 25 in place of the several inflation/displacement modules 3. The perforations may have any form such as circular, square, or rectangular or the like, and may pass partly or completely through the sheet, and may be in an horizontal or vertical form leaving adequate material for the inflation and, where intended, displacement control functions. The material of the perforated sheet 25 which remains between the perforations 24 may be contoured to equalize stress across the bonding surface when the foam is to be adhered to the inside 9 of the bottom 1 and top 2 covers. FIG. 4e shows another construction which utilizes a sheet of open-cell foam or other suitable material 23. Modules 3 may be formed or machined as part of sheet 23 or bonded to the sheet 23. Sheet 23 reduces convection currents within the mattress enclosure. The single unit form shown in FIGS. 4d and 4e may be utilized to advantage during manufacturing to facilitate assembly.
The spacing of the resilient modules (or perforated sheet void spaces) is influenced by a number of factors. Placement of the displacement control modules is principally determined by: a) the external forces which are expected to be applied to the mattress which determine the internal pressure which must be handled and therefore the strength of the cover materials, modules 3, and their associated bond; b) the degree of billowing (or ballooning) of the cover which is acceptable; c) whether contoured or flat module bonding surfaces are to be used; and d) whether self-unrolling is to be facilitated. For a typical air mattress for use in camping and the like which may have a width of 20 to 25 inches, intermodule (on center) spacing of less than about 5 inches has been found to be effective. As intermodule spacing is reduced billowing of the cover surface(s) decreases. In general, comfort usually increases as intermodule spacing is reduced. An intermodule spacing of about 1 to 2.5 inches has been found to provide an effective balance between cover billowing and manufacturing complexity. In a typical camping mattress this works out to about 8 to 20 rows of modules. Module width generally may be decreased as the number of modules increases.
Relatively large numbers of very narrow displacement control modules (less than about 1/2 inch for sleeping mattresses) reduce the need for bonding surface contouring. For instance, four 1/4 inch wide strips on 1 inch centers may be substituted for one 1 inch wide contoured strip on a 4 inch center. Each strip carries a relatively smaller portion of the overall tension between the bottom and top cover 1 and 2 elements. As the spacing decreases, cover distortion, or rounding of the surface also decreases. Further, as the module width is reduced, the relative quantity of material at the center of the module is reduced relative to the edge materials. The ability of the resilient materials to elongate (stretch) when placed under tension serves to equalize the remaining stress imbalances across the module's cross-section. During storage the relatively narrow modules tend to buckle when compressed spreading themselves over a wider area leading to a smaller stored thickness.
Other module configurations will be affected by the method of application, material characteristics, and the desired inter-module spacing. Thus although the size and number of these modules is dependent upon the material selected, the intended application, desired reliability, and associated assembly effort, the size and number for a particular application may be determined readily by routine experimentation. For the camping mattress application described above, when using open-cell polyurethane foam, the preferred module bonding surface 21 (FIG. 4a and 4b) size will be approximately 1 to 4 square inches (each end) for contoured discrete modules; 0.1 to 1 square inch (each end) for uncontoured discrete modules; approximately 0.675 to 1.25 inch wide for relatively long contoured strips; or 0.1 to 0.5 inch wide for uncontoured relatively long strips.
Where relatively long strip modules are utilized, the strip's orientation relative to the mattress length has a significant impact upon the mattress's rolled size and upon the ability of the mattress to self-unroll. In general, a longitudinal orientation maximizes the ability of the mattress to self-unroll. When rolled, the longitudinal resilient material is concentrated in a portion of the mattress' rolled width, thereby increasing the mattress' rolled diameter. Transverse orientation of the strips across the mattress width reduces the rolled size at the expense of reduced self-unrolling capability (except where relatively wide blocks or semirigid covers are used, increasing overall weight). Orientations selected somewhere between longitudinal and transverse provide the best balance between self-unrolling and rolled size. These orientations distribute the resilient material across the stored mattress. Configurations with a moderate serpentine pattern have been found effective for application as a portable mattress. Serpentine patterns which repeat more frequently (every few inches) have also been found effective. Where the strips are constructed to naturally retain their pattern, frequent orientation changes provide additional module dimensional rigidity reducing material mis-orientation during construction. Experimentation has indicated that patterns which vary the strip's orientation such that the strip is offset by as little as 1/4th its width at any point along its length provides a related benefit. Where discrete modules are utilized, placement is selected to distribute the resilient material across the rolled-up or folded mattress when stored. Where storage will involve folding, the modules are positioned such that their distribution is generally equal when folded.
Beginning with a rolled (stored) mattress, the method of operation is as follows. The user places the rolled mattress on the ground, opens valve 4, and unrolls the mattress. Mattresses utilizing resilient strips rather than rows of resilient modules will more readily unroll on their own. Folded mattresses may first be shaken out. Where additional subchambers 43 are configured to facilitate self-inflation, the user inflates them (and closes associated valve), thereby extending the mattress. This allows the free entry of air or other liquid into the enclosed mattress chamber 7 thereby allowing expansion of the resilient inflation/displacement control modules from their compressed (collapsed) condition. This expansion of the modules forces apart the bottom and top covers 1 and 2. When the mattress is fully expanded, the valve 4 is closed to retain the mattress in the inflated mode.
When the user is ready to stow the mattress, the valve 4 is opened (if provided, subchamber(s) 43 is also opened). The mattress then is rolled or folded in the direction of the valve 4, forcing air or liquid out of the mattress. When the mattress has been completely rolled or folded, the valve 4 is closed which helps to maintain the mattress in the rolled or folded state.
The optional pressure control chamber 30 presented in FIG. 5 is a subchamber located within the main mattress chamber 7. Alternatively, it could be configured as a separate external chamber linked to the main mattress chamber 7. Where multiple mattress chambers are configured, pressure control chambers may be within any one, or more, of the chambers. The chamber's shell 33 may be constructed of any flexible air-impervious material such as coated nylon, rubberized fabrics, polyethylene film or the like. The surface of this chamber having an opening 32 may be bonded to the inside 9 of one of the covers. One or more of the opening(s) 32 between the interior of the chamber 35 and the outside atmosphere 11 is provided within this bonded area. The chamber 30 is filled with a resilient material 31. The chamber 30 is structured to enable the user to select the quantity and resilience of the material 31 to reflect the user's weight and comfort preferences and then insert it into the chamber 30. Resilience characteristics may be consistent throughout the chamber(s) or varied to increase resistance to compression as the pressure increases. After filling the chamber 31, the opening(s) 32 is partially closed to retain the resilient material 31 but allow continued air exchange between the chamber 30 and the atmosphere 11. This chamber serves dual purposes. First, it minimizes the effect of sudden localized loads placed on the mattress, through compression of the chamber which allows relief of moderate overpressure conditions. An added benefit of the chamber 30 is to assist in maximizing user comfort. When the user reclines on the mattress, pressure points are created at several locations along the body's contact area with the mattress. Further, the number and size of these pressure points varies with the position of the user (lying on the back, side, or stomach). The pressure points are somewhat relieved by the compression of the fluid within the mattress and the localized deflection of the mattress cover. This response can be optimized by varying the quantity of fluid within the mattress for selected weight disposition profiles. This response can be optimized for one body position but not simultaneously for all positions. The chamber 30 assists this effect by allowing additional controlled pressure relief when the user changes positions.
If additional insulation value and/or comfort is desired, at least one thin lightweight air-impervious sheet 50 may be configured within the main mattress chamber 7 enclosed by covers 1 and 2 in a manner such that it substantially extends to the edges 8 of the enclosure, or extends to an inside cover surface 9 in the area between the edge 8 and the module(s) 3 closest to the edge. Optionally the sheet 50 may be attached in such a fashion as to create two separate chambers. The inflation/displacement control modules are split into upper and lower components and bonded to the sheet 50. When each chamber is provided with its own valve assembly, the user may inflate the two chambers to provide different levels of support. For instance, the bottom chamber could be inflated to provide very firm support while the top is inflated to provide moderate support. The sheet 50 should be positioned so that when the enclosure is inflated and is in use, except for any point(s) where it is attached to the edge(s) 8 of the enclosure, points of contact with cover surfaces 1 or 2 are minimized to reduce heat losses through conduction. Appropriate materials for use as the sheet 50 include but are not limited to heat reflective metallized plastic films such as aluminized Mylar, flexible plastic films of polyethylene or the like, or coated fabrics.
FIG. 9 shows an optional external lumbar support pad assembly 68. The cover 66 may be formed in the same way as a mattress 6 from a tube with sealed ends or from two sheets joined around their edges to form an air-tight envelope. Part of this cover 67 extends under the primary mattress chamber. Attachment means 42, such as Velcro, ties, or snaps is provided to attach this assembly to the bottom 1 of the mattress. This attachment enables the user to relocate the lumbar support pad assembly to suit his/her individual preferences. Resilient materials 65 are contained within this lumbar support pad envelope. The overall thickness of the pad may be approximately 0.5 to 1.5 inches. A valve 69 may be provided to enable the user to alter the amount of air contained within the lumbar pad envelope 68. As with the pressure control chamber 30, this lumbar support pad assembly 68 may be configured to provide for user selection (and fill) of resilient materials 65. To use the lumbar assembly, the user first determines the optimal placement of the assembly to suit personal preference. The assembly is then attached at the appropriate locations using attachment points 42. Alternately, the lumbar pad could be configured so as to attach to the user and turn with the user. Valve assembly 4 is opened to enable inflation of the assembly. If desired, the user may close valve 4 to maintain the inflation when the user reclines upon the lumbar assembly. As with the main mattress, the user may press some of the air out or add additional air prior to closure of the valve. Other uses such as a seat cushion augmentation are also applicable.
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An inflatable enclosure useful as a matress is described which has first (bottom) and second (top) broad surfaces connected at their edges to form the enclosure, the bottom being formed of a substantially air-impermeable resilient closed-cell foam wherein the thickness and density of the closed-cell foam has been selected to provide semi-rigid characteristics between adjacent points of support and the top being formed of material selected from an air-impermeable resilient closed-cell foam and a flexible air-impervious material, said first surface being connected around its edges to a flexible air-impervious material which is in turn attached around the edges of the second surface to form the enclosure, the enclosure having at least one closable means for admitting a fluid to and releasing fluid from the enclosure.
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This application claims priority under 35 U.S.C. §§ 119 and/or 365 to 0200636-9 filed in Sweden on Feb. 28, 2002; the entire content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to a Cu base alloy, which is resistant or immune to carburization, metal dusting and coking, and resistant to oxidation. The invention is also directed to uses, of said alloy in construction components in CO containing atmospheres, and/or hydrocarbon containing atmospheres, or solid carbon containing processes, as well as articles formed from such alloys.
BACKGROUND OF THE INVENTION
A number of inventions in the past related to reforming processes in the petrochemical industry has led to significant process efficiency improvements. One such example is the development of large pore zeolite catalysts, doped with specific metals, rendering catalysts with a high selectivity suitable for precision reforming and/or synthesis, which for example has made possible more effective and economic production of a range of highly demanded commercial liquids based on hydrocarbon feedstocks. However, the catalysts were soon discovered to be sensitive to sulfur poisoning, leading to techniques to desulfurize the hydrocarbon feed being developed. Later, such catalysts were also found to be quickly deactivated by water, thus corresponding protecting technologies to lower the water content in the process gas streams were also developed.
In turn, the low-sulfur and low-water conditions led to coke formation and plugging within reactor systems, an effect later possible to relate back to a severe form of disintegrating attack on metallic materials of the equipment parts, like furnace tubes, piping, reactor walls, etc. This metal disintegrating mechanism was actually already known since the 1940's as “metal dusting” however, this phenomenon was seldom seen because at the time reforming techniques included high sulfur levels in the process gas and very high reforming and synthesis pressures, (since less effective catalysts were available).
Thus, with the above description of the historic developments as a background, it is understood that, in the petrochemical industry today, there is a need for a solution against the effects, of and the cause for, metal dusting.
As earlier mentioned, metal dusting is a form of carburization where the metal disintegrates rapidly into coke and pure metal. The dusting metal particulates can be transported with the process gas, accumulates downstream on various reactor parts, and throughout the whole reactor system, metastasize catalytic coking that can create blockage.
It is generally appreciated that metal dusting is a large concern in the production of hydrogen and syngas (H 2 /CO mixtures). In these plants, methane and various other higher hydrocarbons are reformed or partially oxidized to produce hydrogen and carbon monoxide in various amounts for use in producing other higher molecular-weight organic compounds. Increased reaction and heat-recovery efficiencies of the processes necessitate operating process equipment at conditions that favor metal dusting.
The need for increased heat recovery in ammonia-synthesis processes has caused metal dusting problems in the heat-recovery section of the reformed-gas system, as well as in the reformer itself.
Metal dusting is also a problem in direct iron-ore reduction plants wherein reformed methane is dried and reheated to enhance ore-reduction efficiencies. Metal dusting occurs in the reformer, reformed-gas reheater and piping up-stream of the ore-reduction system. Metal dusting is also experienced in the heat-treating industry in equipment that handles items being treated (annealed, carburized, etc.). Gases used in heat treating mix with oil residue to form gases that are chemically favorable for metal dusting. Gas mixtures used for carburizing can also cause metal dusting if control of the chemistry of the process is not managed.
Petroleum refineries experience metal dusting in processes involving hydro-dealkylation and catalyst regeneration systems of “plat-former” units.
Other processes wherein metal dusting occurs are nuclear plants that employ carbon dioxide for cooling, the recycle-gas loop equipment of coal-gasification units, in fired heaters handling hydrocarbons at elevated temperatures, ironmaking blast furnaces in steel mills, and fuel cells using molten salts and hydrocarbons.
In recent years, there has been an emphasis on reforming and synthesis technology developments to make possible commercialization of remotely located, so called “stranded gas reserves”. The synthesis step, based on further developments of the Fischer Tropsch process, will require the use of compositions of the synthesis gas that will cause severe metal dusting, with lower steam to carbon ratios and higher CO/CO 2 ratios. However, only small steps this direction have been taken due to lack of material with sufficient resistance to metal dusting.
Other solutions used today to provide protection against metal dusting and reduce coke formation, are the use of advanced nickel or iron base alloys with high amounts of chromium and certain additions of aluminum. Some surface modification methods based on diffusion techniques or coatings through overlay welding, laser-fusion, Chemical Vapor Deposition (CVD), Physical Vapor Deposition (PVD) or spraying has also been tested. Many of these methods involve materials based on transition metals, such as iron, nickel and cobalt, which are known for their catalytic properties that promote coke formation.
There are metals, such as Cu and Sn, that are known to be resistant or immune to carburization and coke formation, but have either a melting point, which is too low or insufficient oxidation resistance. Oxidation resistance is required since the solid coke is periodically removed by oxidation in steam and air. Consequently, the metal surfaces in contact with the carburizing process gas must also have adequate oxidation resistance, which excludes Cu and low alloyed Cu as a useful carburization-resistant material in practice. Even if the decoking step can be excluded in some processes, the start-up procedures after an inspection or other stops inevitably require oxidation-resistant metal surfaces.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a copper base alloy which is resistant or immune to carburization, metal dusting and coking.
It is another object of the invention to provide a copper-base alloy resistant or immune to oxidation, especially resistant in CO-containing atmospheres, and/or hydrocarbon containing atmospheres, solid carbon containing processes such as gasification of solid carbonaceous materials, thermal decomposition of hydrocarbons and catalytic reforming, particularly, catalytic reforming under low-sulfur, and low-sulfur and low-water conditions.
It is a third object of the invention to provide a copper base alloy which will not catalytically activate the formation of solid coke.
It is a further object of the invention to provide a copper base alloy which is resistant or immune to carburization, metal dusting and coking, for use in CO-containing atmospheres, and/or hydrocarbon containing atmospheres, solid carbon containing processes such as gasification of solid carbonaceous materials, thermal decomposition of hydrocarbons and catalytic reforming, particularly, catalytic reforming under low-sulfur, and low-sulfur and low-water conditions.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows diagrammatically the weight loss of some comparative samples and one example of the present invention, after exposure at 650° C. over a period of time of 1000 hours (4 cycles to RT) in 25CO+3H 2 O+H 2 .
DETAILED DESCRIPTION OF THE INVENTION
Exemplary embodiments of the present invention will now be described.
Aluminum
Aluminum should be added in an amount up to 15 wt. %, preferably up to 13 wt. %, most preferably up to 8 wt. %, but not less than 2 wt. %, preferably not less than 4 wt. %.
Silicon
Silicon promotes the protective effect of aluminum in this type of alloy by forming aluminum silicate, which has a higher formation rate compared to that of pure alumina. In this type of alloy, the lower starting temperature for the formation of a protective oxide is favorable. Therefore the content of silicon should be up to 6 wt. %, preferably up to 4 wt. %. The content of Si should preferably not be below 2 wt. %.
Magnesium
Magnesia has the same properties as aluminum in that it would reduce the oxidation rate of copper. Therefore, magnesium could to some extent replace aluminum in the alloy. The content of magnesium should therefore be limited to ≧0–6 wt. %, preferably up to 4 wt. %.
Reactive Additions
In order to further increase the oxidation resistance at higher temperatures, it is common practice to add a certain amount of reactive elements, such as Rare Earth Metals (REM), e.g.—yttrium, hafnium, zirconium, lanthanum, and/or cerium. One or more of this group of elements should be added in an amount not exceeding 0.3 wt. %.
Other Additions
The transition metals, in particular iron, nickel and cobalt are known to have a strong catalytic effect on the formation of solid coke. Therefore the content of each of these elements each in the alloy of the present invention should not exceed 1 wt. %.
Copper
The main component, which makes up the balance of the alloy of the present invention, is copper. Copper is known to be inert with respect to catalytic activity and coking. Until today it has not been possible to use copper in these applications, due to its high oxidation rate when in contact with oxygen.
The alloy may comprise up to 98 wt. % Cu. According to one at least 73 wt. % Cu.
Further, the alloy may comprise normally occurring alloying additions and impurities.
The alloy material can be processed as construction material in the shape of tubes, pipes, plate, strip and wire.
A person skilled in the art understands that the alloy of the present invention may need a load-bearing component at elevated temperatures, i.e. temperatures above approximately 200° C. For this purpose the material can be processed as one component in a composite or bimetallic composite used as construction material formed into different shapes as mentioned above.
An alloy according to the present invention is especially well-suited for use in CO-containing atmospheres and/or hyrocarbon-containing atmospheres, or solid carbon-containing processes, for example, gasification of solid carbonaceous materials, thermal decomposition of hydrocarbons, and catalytic reforming particularly under low-sulfur and/or low water conditions at elevated temperatures such as 1000° C., 1020° C., or 1049° C.
EXEMPLARY EMBODIMENTS AND COMPARATIVE EXAMPLES
Static laboratory exposures were performed in a tube furnace in a highly carburizing atmosphere. The metal dusting resistance was evaluated between standard grade stainless steels and a Cu-base alloy A according to the present invention. The chemical compositions of the materials investigated are given in Tables 1 and 2.
Table 1 lists the chemical compositions of the investigated comparative materials and Table 2 lists the composition of an example “A” of the present invention, All contents are given in wt. %.
TABLE 1
Chemical composition of the comparative materials
Example
no.
C
Cr
Ni
Mo
N
Si
Mn
P
S
Ti
Ce
304 L
0.01
18.35
10.15
0.39
0.043
0.42
1.26
0.024
0
(bar)
304 L
0.015
18.20
10.10
0.39
0.043
0.43
1.42
0.021
0.001
—
—
(sheet)
Alloy
0.063
20.37
30.10
0.05
0.009
0.73
0.53
0.009
0.001
0.5
—
800 HT
353 MA
0.052
25.10
34.10
0.20
0.175
1.56
1.40
0.020
0.001
—
0.06
TABLE 2
Chemical composition of alloy A
Al
Ni
Fe
Si
Mg
Cr
V
Bi
Ti
Zr
Mo
Cu
A
8.0
0.02
0.02
0.01
0.005
0.002
0.001
0.0001
0.0001
0.0001
0.0001
balance
The test samples were cut from sheets or bars into shape with dimensions of approximately −10×12×3 mm and prepared by grinding with 600 mesh. Some of the test samples were surface treated by a standard pickling operation in 1.8M HNO 3 +1.6M HF at 50° C. for 8–40 min., or treated by an electropolishing operation (50 g CrO 3 +450 ml ortophosphoric acid, 20V). The samples were cleaned in acetone prior to testing and placed in the cold furnace. To reach a low oxygen partial pressure, pure hydrogen was flushed through the furnace for three hours before introducing the reaction gas and heating to temperature. The gas flow rate was 250 ml/min, which corresponds to a gas velocity over the specimen of 9 mm/s. The temperature stabilizes at 650° C. after 20 minutes heating. The reaction gas, with an input composition of 25% CO+3% H 2 O+72% H 2 . The laboratory exposure was conducted at 650° C./1000 h in a quartz tube furnace with a diameter of 25 mm. Four temperature cycles down to 100–200° C. and back to 650° C., each with a duration time of about 4–5 h, were conducted in order to raise the carbon activity and promote initiation of metal dusting.
The results are presented as weight loss measurements after cleaning the samples from coke and graphite as presented in FIG. 1 , where:
TABLE 3 Description of the comparative examples Example no. Alloy Product condition Surface modification 1 304 L bar annealed 2 304 L bar electro-polished 3 304 L bar ground 4 304 L bar pickled 5 304 L sheet annealed 6 304 L cold rolled sheet ground 7 304 L cold rolled sheet electro-polished 8 800 HT sheet ground 9 800 HT sheet pickled 10 353 MA sheet overpickled 11 Alloy A sheet untreated
As shown in FIG. 1 , all comparative steels (Examples 1–10) suffered from metal dusting with formation of pits and coke during the 1000 h exposure as indicated by a measurable weight gain. However, the alloy of the present invention (Example no. 11) was virtually non-reactive in this atmosphere with no weight change or coke formation. Example 11 has been exposed totally 4000/hours in similar atmospheres (4×1000 h at 650° C.) with no measurable or visible changes.
While the present invention has been described by reference to the above-mentioned embodiments certain modifications and variations will be evident to those of ordinary skill in the art. Therefore, the present invention is to be limited only by the scope and spirit of the appended claims.
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A copper base alloy, which is resistant or immune to carburization, metal dusting and coking, and resistant to oxidation, the alloy having the following composition (all contents in weight %):
Al >0–15 Si 0–6 Mg 0–6 one or more of the group of Rare Earth Metal (REM), yttrium, hafnium, zirconium, lanthanum, cerium) up to 0.3 wt. % each; Cu balance; and normally occurring alloying additions and impurities. Related articles of manufacture and methods are also described.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is based on and incorporates herein by reference German Patent Application No. DE 10 2006 058459.7 filed on Dec. 12, 2006.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method for detecting methylisothiocyanate and to a device for performing the method.
[0003] It is often necessary for soil used in agriculture to be fumigated before the next sowing or replanting, for instance by treatment with a fungicide or nematicide. For instance, methylisothiocyanate (MITC) is used to prepare soils both in greenhouses and on open land for the cultivation of vegetables.
[0004] When Dazomet is used, methylisothiocyanate is released slowly through the moisture of the soil. MITC is the actual biologically effective agent in this case. The use of metam-sodium (sodium-M-methyldithiocarbamate) as a soil fumigant is also known. Metam-sodium likewise releases MITC as the actual active ingredient.
[0005] MITC is a solid at room temperature (melting point 32 to 38° C.) and evaporates slowly and in the process destroys animal pests, fungi, and plants in the soil, so that useful plants, especially vegetables, can germinate and grow without competition. MITC is toxic both to humans and to the useful plants. It is therefore important to protect humans; moreover, the soil must be free of MITC before sowing.
[0006] After each use of a soil decontaminant, a certain waiting period must be observed until resowing or replanting of useful and cultivated plants, in order to assure that the soil decontaminant has decomposed extensively enough that there is no need to fear adverse effects on the resowing or replanting. For the farmer, it is of decisive importance to obtain a reliable statement about the length of the waiting period.
[0007] The detection of isothiocyanates with inorganic reagents is known per se. For instance, former East German Patent Disclosure DD 285 196 describes a test paper for detecting isocyanates and isothiocyanates, which comprises a paper that is saturated with pyridinium salts. For detecting the aforementioned substances, the test paper is put into contact with the substance to be tested, and then, by vapor deposition of ammonia, an intensive yellowish-orange to orange-red/brown coloration develops.
[0008] The known detection methods, however, have proved to be insensitive and/or too expensive in practice.
BRIEF DESCRIPTION OF THE INVENTION
[0009] It is therefore the object, among others, of the present invention to make an easily performed method available for determining methylisothiocyanate for ambient air, in particular close to the ground and especially preferably for interiors, as in greenhouses, for instance, which makes it possible to determine the quantity of methylisothiocyanate present simply, reliably, and with the requisite sensitivity.
[0010] The method for detection is needed especially in order to ascertain whether it is safe to enter greenhouses, for instance, without protecting equipment like gas masks. By means of soil air analysis (analysis of air in the soil to measure substances which are outgased by the soil), it is also possible to ascertain whether the soil tested is free of MITC.
[0011] Surprisingly, it has now been discovered that this object is attained using a detection reagent, in particular a colorimetric indicator, which operates on the basis of palladium sulfate in an acidic environment, preferably sulfuric acid. The detection reagent forms the indication layer, possibly together with a substrate and optionally other substances. The indication layer is preferably part of a transparent glass test tube.
BRIEF DESCRIPTION OF THE DRAWING
[0012] FIG. 1 is a schematic illustration of an example embodiment of a device according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] As mentioned above, the present invention provides an easily performed method for determining methylisothiocyanate for ambient air, in particular close to the ground and especially preferably for interiors, as in greenhouses, for instance. The invention makes it possible to determine the quantity of methylisothiocyanate present simply, reliably, and with the requisite sensitivity using a detection reagent, in particular a colorimetric indicator, which operates on the basis of palladium sulfate in an acidic environment, preferably sulfuric acid. The detection reagent forms the indication layer, possibly together with a substrate and optionally other substances. The indication layer is preferably part of a transparent glass test tube 2.
[0014] The detection reagent is reduced by MITC (presumably to palladium). The result is a color change from yellow to brownish gray. The palladium sulfate is preferably applied to an inert substrate.
[0015] To make the measurement as independent as possible of humidity, the indication layer 5 may also be preceded by a dry layer 1, for instance comprising calcium chloride, optionally also on an inert substrate. The dry layer is either placed in a separate tube or in the same tube as the indication layer.
[0016] With this test tube, MITC can be measured in the desired concentration ranges quickly, economically, and on-site. With the aid of the method of the invention, it is successfully possible to detect MITC in the ambient air in the range from 0.1 to 100 ppm, and in particular 0.2 to 10 ppm (ppm=mL/m 3 or mL/1000 L). The substrate material is preferably a granular material and may for instance be silica gel or quartz glass grit.
[0017] Atmospheric MITC can thus be determined quantitatively as well by the intake of a defined gas volume by the test tube.
[0018] The test tube 2 preferably has two tips that can be broken off. The test tube includes an indication layer 5 that contains the aforementioned indicator or the detection reagent, and the test tube is optionally also provided with a color scale or measuring scale, so that the concentration of MITC can be determined from the progression of the color trace (moving color front/discoloration of the tube). When the tips have been broken off, a defined quantity of gas 4 can flow through the test tube, for instance by means of a hand pump 3 mounted on the end of the tube.
[0019] In terms of the flow direction, there is preferably first a preliminary layer 1 and downstream of it an indication layer 5. The two layers may be separated from one another by an intermediate layer that comprises one or more gas-permeable retainer elements, e.g. an element made from ceramic (or other materials) which fixes (or mounts) the layers in the glass tube. The preliminary layer 1 contains the drying agent, for instance between at least two retainer elements, approximately in the form of a quartz glass grit layer, a glass frit base, or a spun-glass layer. The retainer elements have the function of preventing the preliminary layer and indication layer from trickling through the retainer elements.
[0020] In this embodiment, the test tube has a separate preliminary layer 1 containing the drying agent and optionally a suitable trap, e.g. filter layer, for binding interfering substances. The quantity of the gas sample 4 flows through the preliminary layer and leaves the preliminary layer in the form of an (essentially) dried gas, freed of interfering substances if applicable, and flows toward the indication layer 5 containing the indicator.
[0021] The preliminary layer may also be part of a separate tube that is connected to the indicator tube, for instance only shortly before the measurement. In this embodiment, a preliminary tube is connected upstream of the actual test tube. The tubes are connectable to one another or communicate with one another for instance through a hose.
[0022] If desired, the preliminary layer and indication layer may be provided with a valve element that opens only during the flow through the tube. In an expedient feature of the invention, the valve element may comprise a spring-loaded cup valve or ball valve. This valve then functions in a simple way as a check valve.
[0023] The indication layer may be produced for instance by dissolving the palladium sulfate in sulfuric acid and applying it to quartz glass as a substrate. Small quantities (up to approximately 0.1 ml of the solution on 100 g of quartz glass) become uniformly distributed on the substrate, and the preparation remains pourable.
[0024] It has been found that nitric acid in the presence of sulfuric acid, where the nitric acid is used in minimal quantities compared to the sulfuric acid, improves the storage stability of the indicator, among other factors.
EXPERIMENTAL EXAMPLE
[0025] The production of a substrated indicator is done as follows: A PdSO 4 solution containing 0.8 g PdSO 4 , 7.5 ml water and 2.5 ml H 2 SO 4 and 1 ml of 1% HNO 3 was prepared. As the substrate, 200 g of quartz glass grit was used, which was mixed with 100 μl of the above solution for 30 minutes.
[0026] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A device and method in which the gas specimen to be investigated is exposed to one or more indicators for qualitative or quantitative detection of methylisothiocyanate, characterized in that at least one indicator is palladium sulfate.
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REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of copending application Ser. No. 379,047 filed Jul. 13, 1989, which in turn is a continuation-in-part of application Ser. No. 089,362 filed Aug. 25, 1987, both now abandoned.
BACKGROUND OF THE INVENTION
The present invention is directed to a method, compositions, and compounds for modulating animal brain excitability via the gamma-aminobutyric acid (GABA)/benzodiazepine (BZ) receptor-chloride ionopore complex (GBR complex).
Brain excitability is defined as the level of arousal of an animal, a continuum that ranges from coma to convulsions, and is regulated by various neurotransmitters. In general, neurotransmitters are responsible for regulating the conductance of ions across neuronal membranes. At rest, the neuronal membrane possesses a potential (or membrane voltage) of approximately -80 mv, the cell interior being negative with respect to the cell exterior. The potential (voltage) is the result of ion (K + , Na + , Cl - , organic anions) balance across the neuronal semi-permeable membrane. Neurotransmitters are stored in presynaptic vesicles and are released under the influence of neuronal action potentials. When released into the synaptic cleft, an excitatory chemical transmitter such as acetylcholine will cause membrane depolarization (change of potential from -80 mv to -50 mv). This effect is mediated by post-synaptic nicotinic receptors which are stimulated by acetylcholine to increase membrane permeability to Na + ions. The reduced membrane potential stimulates neuronal excitability in the form of a post-synaptic action potential.
In the case of the GBR complex, the effect on brain excitability is mediated by GABA, a neurotransmitter. GABA has a profound influence on overall brain excitability because up to 40% of the neurons in the brain utilize GABA as a neurotransmitter. GABA regulates the excitability of individual neurons by regulating the conductance of chloride ions across the neuronal membrane. GABA interacts with its recognition site on the GBR complex to facilitate the flow of chloride ions down a concentration gradient of the GBR complex into the cell. An intracellular increase in the levels of this anion causes hyperpolarization of the transmembrane potential, rendering the neuron less susceptible to excitatory inputs (i.e., reduced neuron excitability). In other words, the higher the chloride ion concentration, the lower the brain excitability (the level of arousal).
It is well-documented that the GBR complex is responsible for the mediation of anxiety, seizure activity, and sedation. Thus, GABA and drugs that act like GABA or facilitate the effects of GABA (e.g., the therapeutically useful barbiturates and benzodiazepines (BZs) such as Valium) produce their therapeutically useful effects by interacting with specific regulatory sites on the GBR receptor complex
It has also been observed that a series of steroid metabolites interact with the GBR receptor complex to alter brain excitability (Majewska, M. D. et al., "Steroid hormone metabolites are barbiturate-like modulators of the GABA receptor," Science, 232:1004-1007, 1986; Harrison, N. L. et al., Structure-activity relationships for steroid interaction with the gamma-aminobutyric acid-A receptor complex," J. Pharmacol. Exp. Ther., 241:346-353, 1987). prior to the present invention, the therapeutic usefulness of these steroid metabolites was not recognized by workers in the field due to an incomplete understanding of the potency and site of action. Applicants' invention relates to a pharmaceutical application of the knowledge gained from a more developed understanding of the potency and site of action of certain steroid compounds.
The ovarian hormone progesterone and its metabolites have also been demonstrated to have profound effects on brain excitability (Backstrom, T. et al., "Ovarian steroid hormones: effects on mood, behaviour and brain excitability," Acta Obstet. Gynecol. Scand Suppl. 130:19-24, 1985; Pfaff, D. W. and McEwen, B. S., "Actions of estrogens and progestins on nerve cells," Science, 219:808-814, 1983; Gyermek, et al., 1968, "Structure-activity relationship of some steroidal hypnotic agents," J. Med. Chem. 11:117). The levels of progesterone and its metabolites vary with the phases of the menstrual cycle. It has been well-documented that progesterone and its metabolites decrease prior to the onset of menses. The monthly recurrence of certain physical symptoms associated with the onset of menses has also been well documented. These symptoms, which have become associated with premenstrual syndrome (PMS) include stress, anxiety, and migraine headaches (Dalton, K., Premenstrual Syndrome and Progesterone Therapy, 2nd edition, Chicago: Chicago Yearbook, 1984). Patients with PMS have a monthly recurrence of symptoms that are present in premenses and absent in postmenses.
In a similar fashion, a reduction in progesterone has also been temporally correlated with an increase in seizure frequency in female epileptics (i.e., catamenial epilepsy; Laidlaw, J., "Catamenial epilepsy," Lancet, 1235-1237, 1956). A more direct correlation has been observed with a reduction in progesterone metabolites (Rosciszewska et al., "Ovarian hormones, anticonvulsant drugs and seizures during the menstrual cycle in women with epilepsy," J. Neurol. Neurosurg. Psych., 49:47-51, 1986). In addition, for patients with primary generalized petit mal epilepsy, the temporal incidence of seizures has been correlated with the incidence of the symptoms of premenstrual syndrome (PMS) (Backstrom, T. et al., "Production of 5-alpha-pregnane-3,20-dione by human corpus lutem," Acta Endrocr. Suppl. 256:257, 1983).
A syndrome also related to low progesterone levels is postnatal depression (PND). Immediately after birth progesterone levels decrease dramatically leading to the onset of PND. The symptoms of PND range from mild depression to psychosis requiring hospitalization; PND is associated with severe anxiety and irritability. PND-associated depression is not amenable to treatment by classic antidepressants and women experiencing PND show an increased incidence of PMS (Dalton, K., 1984, op. cit.).
Collectively, these observations imply a crucial role for progesterone in the homeostatic regulation of brain excitability, which is manifested as an increase in seizure activity or symptoms associated with catamenial epilepsy, PMS, and PND. The correlation between reduced levels of progesterone and the symptoms associated with PMS, PND, and catamenial epilepsy (Backstrom, et al., 1983, op. cit.; Dalton, K., 1984, op. cit.) has prompted the use of progesterone in their treatment (Mattson, et al., "Medroxyprogesterone therapy of catamenial epilepsy," in Advances in epileptology: XVth Epilepsy International Symposium, Raven Press, New York, 279-282, 1984, and Dalton, K., 1984, op. cit.). However, progesterone is not consistently effective in the treatment of the aforementioned syndromes. For example, no dose-response relationship exists for progesterone in the treatment of PMS (Maddocks, et al., "A double-blind placebo-controlled trial of progesterone vaginal suppositories in the treatment of premenstrual syndrome," J. Obstet. Gynecol. 154:573-581, 1986; Dennerstein, et al., British Medical Journal, 290:16-17, 1986).
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood and its advantages appreciated by those skilled in the art by referring to the accompanying drawings wherein
FIGS. 1A and 1B are plots of the binding percentage of [ 35 S] t-butylbicyclophosphorothionate vs. log concentration of alphaxalone and GABA;
FlGS. 2A and 2B are plots of the binding percentage of [ 35 S] t-butylbicyclophosphorothionate vs. time;
FIG. 3 is a plot showing the effect of a single dosage of pentobarbital on 5-alpha-pregnan-3-alpha-ol-20-one modulation of [ 3 H] flunitrazepam binding in rat hippocampal homogenates;
FIG. 4 is a bar graph of the time to onset of myoclonus vs. different concentrations of steroid compounds useful in the present invention; and
FIG. 5 is a plot showing the effect of progesterone metabolites and promogesterone (progestin R5020) on [ 3 H] R5020 binding to the progesterone receptor in rat uterus.
SUMMARY OF THE INVENTION
The present invention is directed to a method, compositions, and compounds for modulating brain excitability. More particularly, the invention relates to the use of 3-hydroxylated-5-reduced steroid derivatives, acting at a newly identified site on the GBR complex, to modulate brain excitability in a manner that will alleviate stress, anxiety, and seizure activity. Compositions and compounds effective for such treatment are within the scope of the invention.
The compounds used in and forming part of the invention are modulators of the excitability of the central nervous system as mediated by their ability to regulate chloride ion channels associated with the GABA-benzodiazepine receptor complex. Applicants' experiments have established that the compounds used in and of the invention have anti-convulsant activity similar to the actions of known anxiolytic agents such as the benzodiazepines, but act at a distinct site on the GBR complex.
The relationship of endogenous metabolites of progesterone to processes associated with reproduction (estrus cycle and pregnancy) is well established (Marker, R. E., Kamm, O., and McGrew, R.V., "Isolation of epi-Pregnanol-3-one-20 from human pregnancy urine," J. Am. Chem. Soc. 59, 616-618, 1937). Prior to the present invention, however, it was not recognized how to treat disorders by modulating brain excitability. Therefore, this invention is directed to methods, compositions, and compounds to treat disorders by modulating brain excitability. Representative disorders treated in the present invention are epilepsy, anxiety, pre-menstrual syndrome (PMS), and post-natal depression (PND).
DETAILED DESCRIPTION OF THE INVENTION
The compounds of and used in the invention are various ester, oxime, and thiazolidine derivatives of 3-hydroxylated-5-reduced-pregnan-20-ones, 5-reduced-3,21-pregnanediol-20-ones, and 5-reduced-3,20-pregnandiols having a substituent in the 9-position, which derivatives are referred to as prodrugs by those skilled in the art of pharmaceutical preparations. The expression "prodrug" denotes a derivative of a known active drug whose derivative enhances the delivery characteristics and the therapeutic value of the drug and is transformed into the active drug by an enzymatic or chemical process; see Notari, R. E., "Theory and Practice of Prodrug Kinetics," Methods in Enzymology, 112:309-323 (1985) and Bodor, N., "Novel Approaches in Prodrug Design," Drugs of the Future, 6(3):165-182 (1981). It should be noted that some of the synthetic derivatives forming part of the present invention may not be true prodrugs because of their intrinsic activity.
Our studies (Gee, K. W., et al., "GABA-dependent modulation of the C1 ionophore by steroids in rat brain," European Journal of Pharmacology, 136:419-423, 1987) have demonstrated that the 3-hydroxylated-5-reduced steroids used in the invention are orders of magnitude more potent than others have reported (Majewska, M. D., et al., 1986, op. cit. and Harrison, N. L., et al., 1987, op. cit.) as modulators of the GBR complex. Our in vivo experimental data demonstrate that the high potency of these steroids allows them to be therapeutically useful in the modulation of brain excitability via the GBR complex. The most potent steroids useful in the present invention include major metabolites of progesterone. These steroids can be specifically used to modulate brain excitability in stress, anxiety, and seizure disorders. Furthermore, we have demonstrated that these steroids interact at a unique site on the GBR complex which is distinct from other known sites of interaction (i.e., barbiturate, benzodiazepine, and GABA) where therapeutically beneficial effects on stress, anxiety, sleep, and seizure disorders have been previously elicited (Gee, K. W. and Yamamura, H. I., "Benzodiazepines and Barbiturates: Drugs for the Treatment of Anxiety, Insomnia and Seizure Disorders," in Drugs in Central Nervous System Disorders, pages 123-147, D. C. Horwell, ed., 1985). The compounds of the present invention work in the same way.
The progesterone derivatives of this invention are those having the structural formula: ##STR1## wherein R1 is:
(1) a pharmaceutically acceptable ester ##STR2## wherein R7 is a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical, and Y is either a divalent oxygen or sulfur linkage. This ester is formed using reactions well known in the art between the hydroxyl group of the naturally occurring compounds discussed above with an organic acid, acid halide, acid anhydride, or ester, wherein the organic acids are for example: acetic, propionic, n and i-butyric, n and i and s and t-valeric, hexanoic, heptanoic, octanoic, nonanoic, decanoic, undecanoic, dodecanoic, cinnamic, benzylic, benzoic, maleic, fumaric, ascorbic, pamoic, succinic, bismethylenesalicylic, methanesulfonic, ethanedisulfonic, oxalic, tartaric, salicylic, citric, gluconic, aspartic, stearic, palmitic, itaconic, glycolic, p-aminobenzoic, glutamic, benzenesulfonic, cyclohexylsulfamic, and 1-methyl-1,4-dihydronicotinic; or
(2) a pharmaceutically acceptable oxime ═N-O-R8 radical wherein R8 is a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical. The radicals are identical to those given in the R7 definition. This oxime is formed by the reaction of a 3-oxo derivative of progesterone by methods well known to the art with an oxyamine; or
(3) a pharmaceutically acceptable acyloxyalkyloxy ##STR3## radical wherein R9 is a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical. The radicals are identical to those given in the R7 and R8 definitions. This acyloxyalkyloxy embodiment is formed by the reaction of the 3-hydroxy group of the naturally-occurring compounds discussed above by methods well known to the art with an organic acyloxyalkyl halide (1-20 carbons) or aryloxyalkyl halide, and, in particular, acetyloxymethyl halide, diacetyloxymethyl halide, or aminoacetyloxymethyl halide;
R2 is:
(1) OH or a pharmaceutically acceptable ester ##STR4## wherein R7 and Y are as defined previously or ##STR5## wherein R9 is as defined previously;
(2) a pharmaceutically acceptable ##STR6## wherein R10, R11, and R12 individually are a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical, or an amide ##STR7## radical wherein R16 and R17 are individually a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical or aromatic radical or heterocyclic radical and n=1-8. An example of a compound of the present invention wherein R11 is an amide is 5-alpha-pregnan-3-alpha-hydroxy-21-(N,N-diethylsuccinamate-20-one. These compounds are formed by reacting the 21-hydroxy metabolite of progesterone in accordance with methods known in the art with an alkyl halide or organic acid, such as acetic, propionic, n and i-butyric, n and i and s and t-valeric, hexanoic, heptanoic, octanoic, nonanoic, decanoic, undecanoic, dodecanoic, cinnamic, benzylic, benzoic, maleic, fumaric, ascorbic, pamoic, succinic, bismethylenesalicylic, methanesulfonic, ethanedisulfonic, oxalic, tartaric, salicylic, citric, gluconic, aspartic, stearic, palmitic, itaconic, glycolic, p-aminobenzoic, glutamic, benzenesulfonic, cyclohexylsulfamic, and 1-methyl-1,4-dihydronicotinic;
(3) a pharmaceutically acceptable ##STR8## wherein R13, R14, and R15, individually are a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical. These compounds are prepared by reacting progesterone or the 20-hydroxy metabolite of progesterone with an alkyl halide or organic acid, such as acetic, propionic, n and i-butyric, n and i and s and t-valeric, hexanoic, heptanoic, octanoic, nonanoic, decanoic, undecanoic, dodecanoic, cinnamic, benzylic, benzoic, maleic, fumaric, ascorbic, pamoic, succinic, bismethylenesalicylic, methanesulfonic, ethanedisulfonic, oxalic, tartaric, salicylic, citric, gluconic, aspartic, stearic, palmitic, itaconic, glycolic, p-aminobenzoic, glutamic, benzenesulfonic, cyclohexylsulfamic, and 1-methyl-1,4-dihydronicotinic in accordance with known methods in the art;
(4) a pharmaceutically acceptable thiazolidine derivative of the 20-oxo position on progesterone having the formula: ##STR9## wherein R18 and R19 are individually a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical, and R20 and R21 are individually hydrogen or a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical, or ##STR10## wherein R22 is H or a C 1 -C 20 straight chain, branched chain, or cyclic aliphatic radical, or aromatic radical, or heterocyclic radical;
R3 is a hydroxy, keto, alkyloxy (1 to 18 carbons), aryloxy, or amino radical;
R4 is an alkyl (preferably 1 to 18 carbons), aryl, halo (such as fluoro, chloro, bromo, or iodo), or trifluroalkyl;
R5 is an alkyl (preferably 1 to 18 carbons), aryl, halo (such as fluoro, chloro, bromo, or iodo), or trifluroalkyl and;
R6 is an alkyl (preferably 1 to 18 carbon atoms), aryl, halo (such as fluoro, chloro, bromo, or iodo), or trifluoroalkyl.
Representative alkyloxy groups for R3 include methoxy, ethoxy, propoxy, butoxy, octoxy, dodecoxy, and octadecoxy. Aryloxy groups useful as R3 moieties are phenoxy, tolyloxy, and the like.
Typical alkyl groups used as R4, R5, and R6 are methyl, ethyl, propyl, butyl, octyl, nonyl, dodecyl, t-butyl, and octadecyl. Representative aryl groups are phenyl, benzyl, tolyl, and naphthyl. Typical trifluoroalkyl groups include trifluoromethyl and trifluoroethyl.
Typical heterocyclic groups are 1-methyl-1,4-dihydronicotinic, piperidinyl, pyridinyl, furanyl, thiophenyl, and pyrazinyl.
The following examples are directed to the preparation of compounds forming part of and used in the present invention.
EXAMPLE 1
Preparation of 3α-hydroxy-5α-pregnan-20-one
The reaction was carried out under a dry N2 atmosphere. Potassium trisamylborohydride solution (KS-Selectide) in THF (6 cc, 5.83 mmol) was introduced into a three neck round bottom flask and cooled to 0° C. 5α-Pregnan-3,20-dione (1.58 g, 5 mmol) dissolved in 10 ml of anhydrous chloroform was added to the cooled reducing agent. The resulting mixture was stirred vigorously for 2 hours at 0° C. and then allowed to equilibrate to room temperature for 1 hour. The reaction was quenched with 3 ml of water and 7 ml of ethanol. The organoborane was oxidized with 5 ml of 6 M NaOH and 7 ml of 30% H 2 O 2 . The reaction mixture was saturated with anhydrous potassium carbonate, and the organic layer was separated. The aqueous phase was neutralized with 0.1 N HCl and extracted with 20 ml of chloroform twice. The combined organic layers were dried over anhydrous MgSO 4 and the solvent removed by rotary evaporation. Acetone was added to effect crystallization to produce a yield of 33%. The product has been identified by co-migration with authentic samples using silica based TLC and capillary GC. Melting point is 174°-175°. Elemental analysis: Calc. C=79.19, H=10.76. Obs. C=78.86, H=10.70, NMR: 200 MHz ppm delta; 0.59 (s)(CH3), 0.77 (s)(CH3). 0.9-2.0 (m) (CH2), 2.1 (s) (CH3--C═O), 2.5 (t) (17-H), 4.02 (t) (3-H equatorial). The preparation method is a modification of the method shown in Gyermek et al., "Steroids CCCX. Structure-Activity Relationship of Some Steroidal Hypnotic Agents," J. Med. Chem., 11:117-125 (1968).
EXAMPLE 2
Preparation of 3-substituted esters
To a given amount of 3α-hydroxy-5α-pregnan-20-one dissolved in chloroform is added a two fold excess of the various acid chlorides (for example: acetyl, propionyl, or butyryl chloride). The reaction is refluxed for 10 to 15 minutes followed by neutralization with 1 N NaOH. Organic layers are washed with water, dried over MgSO 4 , and reduced to dryness with rotary evaporation. The product is recrystallized from an acetone/hexane mixture.
EXAMPLE 3
Preparation of 20-spirothiazolidine derivatives
To a given amount of 3-substituted-5α-pregnan-20-one dissolved in 50 ml of pyridine is added a four fold excess of 1-cysteine or its methyl ester hydrochloride. After purging the system with nitrogen gas, the reaction mixture is stirred overnight at room temperature. The excess pyridine is evaporated and the residue dissolved in 150 ml of methylene chloride and washed with water twice. The organic layer is dried over MgSO 4 . After removing the methylene chloride, the residue is boiled in methanol and filtered hot. The product is recrystallized from an acetone/hexane mixture. See U.S. Pat. No. 4,213,978.
EXAMPLE 4
Preparation of 3α-[(3-pyridiniumcarbonyl)oxy]-5α-pregnan-20-one.
Thionyl chloride (2 ml) is added to 0.7 g (5.7 mmol) of nicotinic acid and the mixture is refluxed for 3 hours. The excess thionyl chloride is removed under reduced pressure, and 10 ml of dry pyridine is then added to the cold residue followed by 1.44 g of 3α-hydroxy-5α-pregnan-20-one. The mixture is heated with continuous stirring at 100° C. for 4 hours. The pyridine is removed in vacuo, and 5 ml of methanol is added to the oily residue. The mixture is cooled, and the solid that crystallizes is filtered and recrystallized from methanol-acetone to give white crystals. See Bodor, "Improved Delivery Through Biological Membranes XIV: Brain-specific, Sustained Delivery of Testosterone Using a Redox Chemical Delivery System," J. Pharmaceutical Sciences, 73(3): 385-389 (1984).
EXAMPLE 5
Preparation of 3α-[(1-methyl-3-pyridiniumcarbonyl)oxy]-5α-pregnan-20-one
To a solution of 1.0 g of 3α-(3-pyridiniumcarbonyl)oxy]-5α-pregnan-20-one in 15 ml of acetone is added 1 ml of methyl iodide, and the mixture is heated at reflux overnight. The yellow material that separates is removed by filtration, washed with acetone and crystallized from methanol-ether to yield yellow crystals. See the Bodor article referred to in Example 4.
It will be obvious to one skilled in the art that the above described compounds may be present as diastereo isomers which may be resolved into d or 1 optical isomers. Resolution of the optical isomers may be conveniently accomplished by gas or liquid chromatography or isolation from natural sources. Unless otherwise specified herein, including the claims, reference to the compounds of the invention, as discussed above, is intended to include all isomers, whether separated or mixtures thereof.
Where isomers are separated, the desired pharmacological activity will often predominate in one of the isomers. As disclosed herein, these compounds display a high degree of stereospecificity. In particular, those compounds having the greatest affinity for the GABA-benzodiazepine receptor complex are those with 3-alpha-substituted-5-alpha-pregnane steroid skeletons. In addition, 3-alpha-substituted-5-beta-pregnane skeletons have been demonstrated to be active. The preferred prodrugs include 3α-hydroxy-5α-pregnan-20-spirothiazolidine and N-methyl-nicotinyl esters of 3α-hydroxy-5α-pregnan-20-one.
The compounds of and used in the invention, that being the nontoxic pharmaceutically acceptable synthetic "prodrug" forms of progesterone have hitherto unknown activity in the brain at the GABA-benzodiazepine receptor complex. The present invention takes advantage of the understanding of this previously unknown activity.
The compounds of the invention may be prepared by any known technique. For example, the naturally occurring metabolites of progesterone may be extracted from various animal excretion sources, e.g., urine. Such extractions are conducted using the following steps: (i) hydrolysis of the urine with HCl; (ii) extraction with toluene; (iii) removal of acidic material from the toluene extract; (iv) elimination of substances other than pregnanediol from the neutral toluene-soluble fraction by precipitations from ethanolic solution with dilute NaOH and with water; and (v) weighing of the purified pregnanediol obtained. See Marrian et al., "The Isolation of Pregnane-3α-ol-20-one," Biochem., 40:376-380 (1947). These extracted compounds may then be chemically altered to form the desired synthetic derivative, or used directly.
The pharmaceutical compositions of this invention are prepared in conventional dosage unit forms by incorporating an active compound of the invention or a mixture of such compounds, with a nontoxic pharmaceutical carrier according to accepted procedures in a nontoxic amount sufficient to produce the desired pharmacodynamic activity in a subject, animal or human. Preferably, the composition contains the active ingredient in an active, but nontoxic amount, selected from about 50 mg to about 500 mg of active ingredient per dosage unit. This quantity depends on the specific biological activity desired and the condition of the patient. The most desirable object of the composition and methods is in the treatment of PMS, catamenial epilepsy, and PND to ameliorate or prevent the attacks of anxiety, muscle tension, and depression common with patients suffering from these central nervous system abnormalities.
The pharmaceutical carrier employed may be, for example, either a solid, liquid, or time release (see e.g. Remington's Pharmaceutical Sciences, 14th Edition, 1970). Representative solid carriers are lactose, terra alba, sucrose, talc, gelatin, agar, pectin, acacia, magnesium stearate, stearic acid, microcrystalline cellulose, polymer hydrogels and the like. Typical liquid carriers are syrup, peanut oil, and olive oil and the like emulsions. Similarly, the carrier or diluent may include any time-delay material well known to the art, such as glyceryl monostearate or glyceryl distearate alone or with a wax, microcapsules, microspheres, liposomes, and hydrogels.
A wide variety of pharmaceutical forms can be employed. Thus, when using a solid carrier, the preparation can be tableted, placed in a hard gelatin capsule in powder or pellet form, or in the form of a troche, lozenge, or suppository. When using a liquid carrier, the preparation can be in the form of a liquid, such as an ampule, or as an aqueous or nonaqueous liquid suspension. Liquid dosage forms also need pharmaceutically acceptable preservatives and the like. In addition, because of the low doses that will be required as based on the in vitro data disclosed herein, timed release skin patches are also a suitable pharmaceutical form for topical administration.
The method of producing anxiolytic, or anticonvulsant activity, in accordance with this invention, comprises administering to a subject in need of such activity a compound of the invention, usually prepared in a composition as described above with a pharmaceutical carrier, in a nontoxic amount sufficient to produce said activity.
During menses, the levels of excreted metabolites varies approximately fourfold (Rosciszewska, et al., op. cit.). Therefore, therapy for controlling symptoms involves maintaining the patient at a more uniform level of progesterone metabolite. Plasma levels of active and major metabolites are monitored during pre-menses and post-menses of the patient. The amount of the compounds, either singly or mixtures thereof, of the invention administered reflects the physiological concentrations which naturally occur post-menses. The route of administration may be any route that effectively transports the active compound to the GABA-benzodiazepine receptors that are to be stimulated. Administration may be carried out parenterally, rectally, intravaginally, intradermally, subliqually, or nasally; the dermal route is preferred. For example, one dose in a skin patch may supply the active ingredient to the patient for a period of up to one week.
The in vitro and in vivo experimental data show that the naturally-occurring metabolites of progesterone and their derivatives interact with high affinity at a novel and specific recognition site on the GBR complex to facilitate the conductance of chloride ions across neuronal membranes sensitive to GABA (Gee et al., 1987).
To those skilled in the art, it is known that the modulation of [ 35 S] t-butylbicyclophosphorothionate ([ 35 S] TBPS) binding is a measure of the potency and efficacy of drugs acting at the GBR complex, which drugs may be of potential therapeutic value in the treatment of stress, anxiety, and seizure disorders (Squires, R. F., et al., "] 35 S]t-Butylbicyclophophorothionate binds with high affinity to brain-specific sites coupled to a gamma aminobutyric acid-A and ion recognition site," Mol. Pharmacol., 23:326, 1983; Lawrence, L. J., et al., "Benzodiazepine anticonvulsant action: gamma-aminobutyric acid-dependent modulation of the chloride ionophore," Biochem. Biophys. Res. Comm., 123:1130-1137, 1984; Wood, et al., "In vitro characterization of benzodiazepine receptor agonists, antagonists, inverse agonists and agonist/antagonists," J. Pharmacol. Exp. Ther., 231:572-576, 1984). We performed an assay to determine the modulation of [ 35 S] TBPS as effected by the compounds of the invention and found that these compounds have high potency and efficacy at the GBR complex, with stringent structural requirements for such activity.
The procedures for performing this assay are fully discussed in: (1) Gee, et al., 1987 op. cit.; and (2) Gee, K. W., L. J. Lawrence, and H. I. Yamamura, "Modulation of the chloride ionopore by benzodiazepine receptor ligands influence of gamma-aminobutryric acid and ligand efficacy," Molecular Pharmacology, 30, 218, 1986. These procedures were performed as follows:
Brains from male Sprague-Dawley rats were removed immediately following killing and the cerebral cortices dissected over ice. A P 2 homogenate was prepared as previously described (Gee, et al., 1986, op. cit.). Briefly, the cortices were gently homogenized in 0.32M sucrose followed by centrifugation at 1000× g for 10 minutes The supernatant was collected and centrifuged at 9000×g for 20 minutes. The resultant P 2 pellet was suspended as a 10% (original wet weight/volume) suspension in 50 mM Na/K phosphate buffer (pH 7.4)+200 mM NaCl to form the homogenate.
One hundred microliter aliquots of the P 2 homogenate (0.5 milligrams (mg) protein) were incubated with 2 nanomolar (nM) TBPS [ 35 S]TBPS (70-110 curies/millimole;, New England Nuclear, Boston, Mass.) in the presence or absence of the naturally occurring steroids and their synthetic derivative prodrugs to be tested. The tested compounds were dissolved in dimethylsulfoxide (Baker Chem. Co., Phillipsbury, N.J.) and added to the incubation mixture in 5 microliter aliquots. The incubation mixture was brought to a final volume of 1 milliliter (ml) with buffer. Non-specific binding was defined as binding in the presence of 2 micromolar TBPS. The effect and specificity of GABA (Sigma Chem. Co., St. Louis, Mo.) was evaluated by performing all assays in the presence of 5 micromolar GABA ± (+)-bicuculline (Sigma Chem. Co.). Incubations maintained at 25° C. for 90 minutes (steady state conditions) were terminated by rapid filtration through glass fiber filters (No. 32, Schleicher and Schuell, Keene, N.H.). Filter bound radioactivity was quantitated by liquid scintillation spectrophotometry. Kinetic data and compound/[ 35 S]TBPS dose-response curves were analyzed by non-linear regression using a computerized iterative procedure to obtain rate constants and IC 50 (concentration of compound at which half-maximal inhibition of basal [ 35 S]TBPS binding occurs) values.
The experimental data obtained for this assay are also published in Gee, et al., 1987. The data discussed in this reference are shown as plots in FIGS. 1A and 1B. These plots show the effect of (+)-bicuculline on alphaxalone (1A) and GABA (1B) modulation of 2 nanomolar [ 35 S]-TBPS binding to rat cerebral cortex. In these FIGS, () represents control without bicuculline; () represents 0.5 micromolar bicuculline;() represents 1.0 micromolar bicuculline; () represents 2.0 micromolar bicuculline; and (Δ) represents 3.0 micromolar bicuculline. In this experiment, the effect of (+)-bicuculline on the ability of alphaxalone or GABA to inhibit the binding of [ 35 S]TBPS was determined. Bicuculline is known to be directly competitive with GABA and a classical parallel shift in the dose-response curves is observed in FIG. 1B. In contrast, the steroid binding site is distinct from the GABA/bicuculline site in FIG. 1A. The shift in dose-response curves induced by (+)-bicuculline when the inhibition of [ 35 S]-TBPS binding is caused by alphaxalone is not linear. This indicates that the GABA and steroid sites do not overlap.
An assay was performed to determine the effect of pentobarbital on the dissociation kinetics of [ 35 S]TBPS in rat cerebral cortical membranes. This assay was performed in accordance with the procedures outlined above. These data indicate that the site of action of the compounds of the invention is unique and distinct from the previously known sites of action for the barbiturates and the BZs. The results of the in vitro assay are shown in FIGS. 2A and 2B. The plots in FIGS. 2A and 2B show the effect of pentobarbital, alphaxalone, or 5-alpha-pregnan-3-alpha-hydroxy-20-one on the dissociation kinetics for 2 nanomolar [ 35 S]-TBPS in cortical P2 homogenates. Dissociation of bound [ 35 S]TBPS was initiated by 2 micromolar TBPS in all cases. Pentobarbital (FIG. 2A) at 30 micromolar induces a biphasic dissociation mechanism which is absent for alphaxalone (300 nanomolar) and 5-alpha-pregnan-3-alpha-hydroxy-20-one (20 nanomolar) (FIG. 2B).
The kinetic rate constants and half lives obtained by this assay are set forth in Table 1. The information presented in Table 1 shows that the barbiturate induces a shift in teh half life of dissociation and the proportion of slow and rapidly dissociating components--hallmark effects of therapeutically useful GABA agonists, barbiturates, and BZs on [ 35 S]TBPS binding (Gee, et al., 1986; Maksay, G. & Ticku, M., "Dissociation of [ 35 S]t-butylbicyclophoporothionate binding differentiates convulsant and depressant drugs that odulate GABAergic transmission," J. Neruochem, 44:480-486, 1985). In contrast, the progesterone metabolite 5-alpha-pregnan-3-alpha-o1-20-one and the progestin alphaxalone do not influence the dissociation kinetics of [ 35 S]TBPS binding. The steroid and barbiturate sites are, therefore, distinct.
TABLE 1______________________________________ Total percent- age of t.sub.1/2 (min) k.sub.-1 (min.sup.-1) specific sitesConditions S R S R S R______________________________________Control 50 ± 6 ± 0.0145 ± 0.131 ± 73 ± 2 30 ± 2 4 1 0.0008 0.01630 nM Na 38 ± 4.4 ± 0.0186 ± 0.158 ± 61 ± 48 ±pentobarbital 3 0.3 0.0015 0.013 6* 6**300 nM 67 ± 4.9 ± 0.0120 ± 0.180 ± 73 ± 4 34 ± 5Alphaxalone 12 1 0.003 ± 0.04020 nM 76 ± 6.4 ± 0.011 ± 0.122 ± 68 ± 3 35 ± 3a-OH-DHP 11 1 0.002 0.030______________________________________ Significantly different from control @ *P < 0.05 and **P < 0.01 by Student's tgest. S and R represent slowly and rapidly dissociating components respectively.
Furthermore, 5-alpha-pregnan-3-alpha-o1-20-one does not interact with pentobarbital in the enhancement of the binding of [ 3 H] flunitrazepam to the BZ receptor in the cortical brain homogenates (FIG. 3) indicating that steroids and barbiturates do not share a common site of action. The data of FIG. 3 were obtained by performing an assay to determine the effect of a single concentration of pentobarbital (1.0 millimolar) on 5-alpha-pregnan-3-alpha-ol-20-one modulation of 0.25 nM [ 3 H] flunitrazepam ([ 3 H]FLU) binding to the BZ receptor in rat hippocampal homogenates. This assay was performed in accordance with the procedures outlined above. Each point on the plot of FIG. 3 represents the mean +SEM of 4-6 independent determinations. The data points in both curves are expressed as percent enhancements of [ 3 H]FLU binding, which is defined as the percentage of [ 3 H]FLU bound in the absence of 5-alpha-pregnan-3-alpha-o1-20-one under the control conditions minus 100%. All assays were performed in the absence of GABA.
The above data demonstrate that the compounds of and used in the invention interact with a novel site distinct from previously defined regulatory sites on the GBR complex.
Various compounds were screened to determine their potential as modulators of [ 35 S]TBPS binding in vitro. These assays were performed in accordance with the above discussed procedures. Based on these assays, we have established the structure-activity requirements for their specific interaction at the GBR complex and their rank order potency and efficacy (Table 2 below).
TABLE 2__________________________________________________________________________ CONTROL +5 μM GABA MAXIMALCOMPOUND IC.sub.50 (nM) IC.sub.50 (nM) INHIBITION__________________________________________________________________________5α-PREGNAN-3α-DL- 20-ONE (EPIALLOPREG- NANOLONE) ##STR11## 230 17 1005α-PREGNAN-3α,20- DIOL (PREGNANDIOL) ##STR12## 359 82 525α-PREGNAN-3α-DL- 11,20-DIONE (ALPHAXALONE) ##STR13## 11000 264 1005α-ANDROSTAN-3α, 17β-DIOL ##STR14## 15000 1000 100PROGESTERONE ##STR15## >10.sup.5 5200 1005α-PREGNAN-3α,21- DIOL-11,20-DIONE ##STR16## >10.sup.5 5500 1005α-ANDROSTAN-17β- DL-3-ONE ##STR17## >10.sup.5 18000 525α-PREGNAN-3β-DL- 20-ONE (ALLOPREGNANOLONE) ##STR18## INACTIVE >10.sup.5 335-PREGNEN-3β-DL- 20-ONE (PREGNENOLONE) ##STR19## INACTIVE >10.sup.5 304-PREGNEN-11β,21- DIOL-3,20-DIONE (CORTICOSTERONE) ##STR20## INACTIVE >10.sup.5 2117β-ESTRADIOL ##STR21## INACTIVE INACTIVE 0CHOLESTEROL ##STR22## INACTIVE INACTIVE 0__________________________________________________________________________
Experiments were also performed to determine the physiological relevance of these interactions by measuring the ability of the compounds of and used in the invention to modulate TBPS-induced convulsions in Swiss-Webster mice. Mice were injected with various doses of the test compounds of the invention, as indicated in FIG. 4, 10 minutes prior to the injection of TBPS. The time to onset of myoclonus (presence of forelimb clonic activity) induced by TBPS was determined by observing each mouse for a period of 45 minutes. Significant differences between the time to onset in control mice vs. steroid-treated mice were determined by Student's t-test. The relative rank order potency and efficacy of these steroids in vivo were well correlated with those values determined in vitro. The anticonvulsant and toxicological profiles of 5α-pregnan-3α-5 o1-20-one (3α-OH-DHP) were determined. In the anticonvulsant screen, mice were injected with various doses of 3α-OH-DHP or vehicle (dimethylsulfoxide) 10 minutes prior to the administration of the following chemical convulsants: metrazol (85 mg/kg); (+)bicuculline (2.7 mg/kg); picrotoxin (3.15 mg/kg); strychnine (1.25 mg/kg); or vehicle (0.9% saline). Immediately after the injection of convulsant or vehicle, the mice were observed for a period of 30 to 45 minutes. The number of animals with tonic and/or clonic convulsions was recorded. In the maximal electroshock test, 50 mA of current at 60 Hz was delivered through corneal electrodes for 200 msec. The ability of 3α-OH-DHP to abolish the tonic component was defined as the endpoint. Sedative potential was determined by a rotorod test 10 minutes after the injection of 3α-OH-DHP where the number of mice staying on a rotating (6 rpm) rod for ≧1 minute in each of 3 trials was determined. The ED 50 (the dose at which the half-maximal effect occurs) dose was determined for each screen. The acute LD 50 (the dose that is lethal to one half of the animals tested) was determined by counting survivors 48 hours after the administration of 3α-OH-DHP. The results are presented in Table 3, infra, and demonstrate that 3α-OH-DHP, in comparison to other clinically useful anticonvulsants, is highly effective with a profile similar to that of the benzodiazepine clonazepam. The sedative liability at anticonvulsant doses is low as shown by comparing the ED 50 values for the rotorod test and (+)bicuculline-induced seizures. The therapeutic index (ratio of LD 50 to ED 50 ) for 3α-OH-DHP is >122 when based on the ED 50 against (+)bicuculline-induced seizures, thus indicating very low toxicity. These observations demonstrate the therapeutic utility of these compounds as modulators of brain excitability, which is in correspondence with their high affinity interactio with the GBR complex in vitro.
TABLE 3__________________________________________________________________________Anticonvulsant and acute toxicological profile of 3α-OH-DHPand those of selected clinically useful anticonvulsants inmice. ED.sub.50 *Compound RR MES MTZ BIC PICRO STR LD.sub.50__________________________________________________________________________3α-OH-DHP 40-100 >300 18.8 ± 1.1 4.1 ± 1.7 31.7 ± 1.1 >300 >500Clonazepam 0.184 93 0.009 0.0086 0.043 NP >6000Phenobarbital 69 22 13 38 28 95 265Phenytoin 65 10 NP NP NP ** 230Progabide*** -- 75 30 30 105 75 3000Valproate 426 272 149 360 387 293 1105__________________________________________________________________________ *All ED.sub.50 values for 3α-OHDHP include the 95% confidence limits. The abbreviations are RR (Rotorod); MES (maximal electroshock); MTZ (metrazol); BIC (bicuculline); PICRO (picrotoxin); STR (strychnine); NP (no protection). **Maximum protection of 50% at 55-100 mg/kg. ***The chemical convulsants in the progabide studies were administered i.v., all data from Worms et al., Gammaaminobutyric acid (GABA) receptor stimulation. I. Neuropharmacological profiles of progabide (SL 76002) and SL 75102, with emphasis on their anticonvulsant spectra, Journal of Pharmacology and Experimental Therapeutics 220: 660-671, 1982. All remaining anticonvulsan data are from Swinyard & Woodhead, General principles: experimental detection, quantification and evaluation of anticonvulsants, in: Antiepileptic Drugs, D. M. Woodbury, J. K. Penry, and C. E. Pippenger, eds., p. 111, (Raven Press, New York), 1982.
The correlations between reduced levels of progesterone and the symptoms associated with PMS, PND, and catamenial epilepsy (Backstrom, et al., 1983, op. cit.; Dalton, K., 1984, op. cit.) led to the use of progesterone in their treatment (Mattson, et al., 1984; and Dalton, 1984). However, progesterone is not consistently effective in the treatment of the aforementioned syndromes. For example, no dose-response relationship exists for progesterone in the treatment of PMS (Maddocks, et al, 1987, op. cit.). These results are predictable when considered in light of the results of our in vitro studies which demonstrate that progesterone has very low potency at the GBR complex, as seen in Table 2, compared to certain metabolites of progesterone.
The beneficial effect of progesterone is probably related to the variable conversion of progesterone to the active progesterone metabolites The use of specific progesterone metabolites in the treatment of the aforementioned syndromes is clearly superior to the use of progesterone based upon the high potency and efficacy of the metabolites and their derivatives (See Gee, et al., 1987, and Table 2 above).
It has also demonstrated that the compounds of and used in the invention lack hormonal side effects by the lack of affinity of these compounds of the invention for the progesterone receptor (FIG. 5). The data plotted in FIG. 5 were obtained by performing assays in accordance with the procedures outlined above to determine the effect of progesterone metabolites and the progestin R5020 on the binding of [ 3 H]R5020 to the progesterone receptor in rat uterus. All points on the plot of FIG. 5 represent the mean of triplicate determinations. The following compounds are those listed in FIG. 5: 5-alpha-pregnan-3-alpha-o1 -20-one (DHP), 5-alpha-pregnan-3-alpha,21-diol-20-one (Th-DOC), and 5-beta-pregnane-3-alpha,20 diol (5 BETA).
While the preferred embodiments have been described and illustrated, various substitutions and modifications may be made thereto without departing from the scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.
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Method, compositions, and compounds for modulating brain excitability to alleviate stress, anxiety, and seizure activity using certain steroid derivatives that act at a newly identified site on the gamma-ammobutyric acid/benzodiazepine receptor-chloride ionpore (GBR) complex.
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This invention relates to a polyvinyl chloride plastisol sealer composition, more particularly a cross-linking polyvinyl chloride plastisol sealer composition which can prevent undesirable cracking of the coating film(s) of intercoat-paint and/or topcoat-paint formed on the layer of the sealer composition, which occurs during the baking and/or cooling steps of the coating films. Said sealer composition is useful as a body-sealer of automobiles in an automobile assembly line.
PRIOR ART
In the automobile assembly line, a sealer is usually used for sealing the automobile body, for example, a certain polyvinyl chloride plastisol composition comprising a polyvinyl chloride resin, a plasticizer, a filler and optionally an adhesive promoter. The sealer is usually used for effecting a watertight and hermetic seal at the joint of panels of the automobile body and exhibits the sealing effects by gelling at the time of baking of the paint in the steps of intercoating and/or topcoating after the application of the sealer. However, during the steps of baking at 140° to 160° C. for 20 to 30 minutes and subsequent cooling thereof, the sealer expands with heating and then shrinks, which causes undesirable cracking of the formed paint-coating films on the sealer and can not give good appearance of the coated paints and further can not exhibit sufficiently the desired sealing effects.
BRIEF DESCRIPTION OF THE INVENTION
The present inventors have intensively studied to find an improved sealer composition which can prevent such undesirable cracking of the coating films on the sealer, and have found that a crosslinking sealer can prevent movement of sealer during the baking and cooling steps and thereby can achieve the desired prevention of cracking of the coating film on the sealer.
An object of the invention is to provide an improved polyvinyl chloride plastisol sealer composition which can prevent undesirable cracking of the coating films on the sealer during =he baking and cooling steps of the intercoat-paint and/or topcoat-paint. Another object of the invention is to provide a crosslinking sealer composition which can inhibit the movement of the the sealer composition and thereby can prevent the undesirable cracking of the paint coating films such as the intercoat and/or topcoat on the sealer. These and other objects and advantages of the invention will be apparent to those skilled in the art from the following description.
DETAILED DESCRIPTION OF THE INVENTION
The polyvinyl chloride plastisol sealer composition of the invention comprises (A) a polyvinyl chloride resin containing a hydroxy group (OH) or a carboxy group (COOH) in the molecule (hereinafter, referred to as "crosslinkable PVC"), (B) a blocked polyisocyanate compound, and (C) an isocyanuric acid compound containing two or more groups selected from epoxy group, hydroxy group (OH) and carboxy group (COOH) in the molecule.
The crosslinkable PVC (component A) includes a copolymer of vinyl chloride with a monomer containing OH or COOH in the molecule (e.g. 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate, 2-hydroxypropyl acrylate, hydroxybutyl vinyl ether, maleic acid, maleic anhydride, acrylic acid, methacrylic acid, etc.). The component A may optionally be incorporated by a-conventional polymer resin for plastisol, such as a conventional polyvinyl chloride resin or vinyl chloride/vinyl acetate copolymer resin.
The blocked polyisocyanate compound (component B) is prepared by blocking a polyisocyanate compound such as aliphatic polyisocyanates (e.g. hexamethylene diisocyanate, lysine diisocyanate, etc.), alicyclic polyisocyanates (e.g. hydrogenated diphenylmethane diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, etc.), aromatic polyisocyanates (e.g. tolylene diisocyanate, diphenylmethane diisocyanate, naphthylene diisocyanate, xylylene diisocyanate, etc.), trimere or dimers of these polyisocyanates, or propolymers which are produced by reacting one of the above polyisocyanates with a compound containing an active hydrogen such as a polyol, with a blocking agent, i.e. a compound containing an active hydrogen, such as alcohols (methanol, ethanol, propanol, butanol, benzyl alcohol, phenyl cellosolve, furfuryl alcohol, cyclohexanol, etc.), phenols (phenol, cresol, xylenol, p-ethylphenol, o-isopropylphenol, p-tert-butylphenol, p-tert-octylphenol, thymol, p-naphthol, p-nitrophenol, p-chlorophenol, etc.), oximes (e.g. formamide oxime, acetamide oxime, methyl ethyl ketone oxime, cyclohexanone oxime, etc.), acid amides (e.g. acetanilide, acetanisidide, acetamide, benzamide, ε-caprolactam, etc.), active methylene-containing acid esters (e.g. dimethyl malonate, diethyl malonate, ethyl acetoacetate, etc.), mercaptanes (e.g. methylmercaptane, thiophenol, tertdodecylmercaptane, etc.), amines (e.g. diphenylamine, phenylnaphthylamine, aniline, carbazole, etc.), imidazoles (e.g. imidazole, 2-ethylimidamole, etc.), carbamates (e.g. phenyl N-phenylcarbamate, 2-oxamolidone, etc.), imines (ethyleneimine, etc.), aulfites (e.g. sodium bisulfite, potassium bisulfite, etc.), and the like. The blocked polyisocyanate compound is de-blocked by heating at the step of baking and gelling, in which there is produced an active isocyanate group (NCO) which participates in the crosslinking reaction with the OH or COOH group of the crosslinkable PVC. The blocked polyisocyanate compound (B) is usually used in an amount of 20 to 60 parts by weight to 100 parts by weight of the crosslinkable PVC.
The isocyanuric acid compound (component C) contains two or more groups selected from epoxy, OH and COOH which participate in the crosslinking reaction with the OH or COOH of the above crosslinkable PVC together with the active NCO of the blocked polyisocyanate compound. The isocyanuric acid compound includes, for example, 1,3,5-triglycidyl isocyanurate, tris-1,3,5-(2-carboxyethyl) isocyanurate, tris-1,3,5-(2-hydroxyethyl) isocyanuate, and the like. The isocyanuric acid compound (C) is usually used in an amount of 5 to 35 parts by weight, preferably 10 to 20 parts by weight, to 100 parts by weight of the crosslinkable PVC. When the amount of the isocyanurlc acid compound is ever 35 parts by weight, the final sealer composition has inferior physical properties (particularly less elongation), and when the amount is less than 5 parts by weight, the composition does not exhibit sufficient crosslinking properties and hence can not show the desired effect for the prevention of cracking of the coating film.
The polyvinyl chloride plastisol sealer composition of the present invention comprises the above mentioned crosslinkable PVC (component A), blocked polyisocyanate compound (component B) and isocyanuric acid compound (component C), and may optionally incorporate any conventional additives, such as plasticizerm (e.g. phthalates such as di(n-butyl) phthalate, octyl decyl phthalate, diisodecyl phthalate, di(2-ethylhexyl) phthalate, butyl benzyl phthalate, dioctyl phthalate (DOP), dinonyl phthalate, diisononyl phthalate (DINP), diheptyl phthalate, dodecyl benzyl phthalate, butylphthalyl-butylglycol, etc.; aliphatic dibasic acid esters such as dioctyl adipate, didecyl adipate, dioctyl sebacate, di(2-ethylnexyl) adipate, diisodecyl adipate, di(2-ethylhexyl) azelate, dibutyl sebacate, di(2-ethylhexyl) sebacate, etc.; phosphates such as tricresyl phosphate, trioctyl phosphate, tributyl phosphate, tri(2-ethylhexyl) phosphate, 2-ethylhexyl diphenyl phosphate, etc.; epoxy plasticizers such as epoxidized soybean oil, epoxidized tall oil fatty acid 2-ethylhexyl esters, etc.; and other conventional polyester plasticizers); fillers (e.g. precipitated calcium carbonate or a product thereof surface-treated with an aliphatic acid or resin acid, ground calcium carbonate, calcium oxide, clay, talc, silica, glass powder, etc.); stabilizers for inhibiting dehydrochloric acid reaction (e.g. metal soap, organic tin compounds, etc.); heat stabilizers (e.g. dibutyl tin laurate, epoxidized soybean oil, Ba or Zn compounds, etc.), pigments (e.g. titanium white, etc.); fire retardants, and the like, which are used in an appropriate amount usually used in the conventional sealer composition.
The sealer Composition of the present invention can mainly be used as a body-sealer of automobiles, but may also be used for other utilities, for example, as an under-body coating material which is used for prevention of injuries to body due to stone chipping on the road during running of automobiles.
EXAMPLES
The present invention is illustrated by the following Examples and Reference Examples but should not be construed to be limited thereto.
EXAMPLES 1 AND 2 AND REFERENCE EXAMPLES 1 TO 3
The materials as shown in the following Table 1 are mixed and the mixture is degassed under reduced pressure to give polyvinyl chloride plastisol sealer compositions.
The evaluation of cracking of the coating film and other properties as shown in Table 1 were carried out in the following manner.
(1) Viscosity: using BH viscometer, with rotor #7, at number of revolution 20 r.p.m., and 20° C.
(2) Adhesion:
The sealer compositions of Examples 1 and 2 and Reference Examples 1 to 3 were each applied in the bead form onto a surface of a steel panel coated by a cationic electrodeposition and subjected to baking and gelling at 120° C. or 140° C. for 30 minutes. After cooling, the sealer layer thus formed was peeled and the adhesion was evaluated by the criteria of CF: cohesive failure, i.e. failure of the sealer, and AP: adhesive failure, i.e. the interfacial failure between the electrodeposited coating layer and the sealer.
(3) Cracking Of the coating films:
The sealer compositions of Examples 1 and 2 and Reference Examples 1 to 3 were each coated in the bead form (10 mmφ half round shape×100 mm) on a surface of a steel panel coated by an electrodeposition and subjected to baking and gelling at 120° C. for 10 minutes. On the sealer composition layer was further coated an intercoat-paint (melamine alkyd resin paint) by spray coating (thickness, about 30 μm), followed by baking and curing by heating at 140° C. for 30 minutes, and further thereon was coated a topcoat-paint (melamine alkyd resin paint) by spray coating (thickness, about 30 μm), followed by baking and curing by heating at 160° C. and 170° C. for 30 minutes respectively, and then, the cracking of the surface of the cured topcoat on the sealer was observed and evaluated by the following criteria:
◯: No cracking, good properties
Δ: Cracking of less than 1 mm width
x: Cracking of more than 1 mm width
(4) Elongation:
The sealer compositions of Examples 1 and 2 and Reference Examples 1 to 3 were each applied in a thickness of 2 nun onto a surface of a release paper and subjected to baking and gelling at 140° C. for 60 minutes. After gelling, the elongation of the sealer composition with #2 Dumbbell in accordance with the method as described in Japanese Industrial Standard (JIB) K6830.
(5) Storage stability:
The sealer compositions of Examples I and 2 and Reference Examples 1 to 3 were each entered in a 250 cc Glass-made vessel and sealed. After keeping the vessel at 40° C. for 5 days, the change of viscosity of the composition was measured. The storage stability of the composition was evaluated by the percentage of the viscosity after being kept at 40° C. for 5 days of the initial viscosity of the sealer composition. When the number of the percentage of viscosity is smaller, and hence, the increase of the viscosity is smaller, it is evaluated that the storage stability is better.
These results are shown in Table 1.
TABLE 1______________________________________ Examples Ref. Examples 1 2 1 2 3______________________________________PVC for plastisol (*1) 200 200 200 300 200Crosslinker PVC (*2) 100 100 100 -- 100Plasticizer (*3) 400 400 400 400 400Surface treated 270 270 270 270 270calcium carbonateCalcium carbonate 300 300 315 300 355Blocked 85 85 85 85 --polyisocyanate (*4)Polyamide resin -- -- -- -- 30(adhesive promoter)(*5)1,3,5-Triglycidyl 15 -- -- 15 15iso-cyanurateTris-1,3,5-(2-hydroxy- -- 15 -- -- --ethyl) isocyanurateOther additives 60 60 60 60 60Total 1430 1430 1430 1430 1430(parts by weight)(1) Viscosity (poise) 900 950 1200 920 750(2) Adhesion120° C. × 30 min. CF CF CF CF AF140° C. × 30 min. CF CF CF CF CF(3) Cracking of the coating film160° C. × 30 min. ∘ ∘ Δ x x170° C. × 30 min. ∘ Δ x x x(4) Elongation (%) 180 180 210 230 150(5) Storage 125 120 120 115 140stability (%)______________________________________ Notes in Table 1: *1: Zeone 121, manufactured by Nippon Zeone K.K. *2: Vinica P100, manufactured by Mitsubishi Kasei Vinyl K.K. *3: Diisononyl phthalate *4: Trimer of hexamethylene diisocyanate blocked with nonylphenol *5: Barsamide 115, manufactured by Henkel Hakusui K.K.
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A polyvinyl chloride plastisol sealer composition comprising (A) a polyvinyl chloride resin containing hydroxy group or carboxy group in the molecule, (B) a blocked polyisocyanate compound, and (C) an isocyanuric acid compound containing two or more groups selected from epoxy group, hydroxy group and carboxy group in the molecule, which is particularly useful for sealing the panels of automobile body without undesirable cracking of the coating films of the intercoat-paint and/or topcoat-paint applied on the sealer.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a vehicle door.
[0002] Motor vehicle doors, for motor cars as well as for trucks, as a rule comprise trim facing towards the vehicle interior. These trims accommodate an actuation lever for the door opening, which is rotatably mounted about a pivot arbor in a bearing block belonging to the door. Here, usually a peripheral gap arises in the region between the actuation lever and the trim which encompasses this.
[0003] In particular with high-quality motor vehicles, it is important that no unsatisfactory gap appearance (gap which is too large, changing gap width) between the actuation lever and connecting parts of the trim occurs.
[0004] At the same time it is a problem that due to the fact that several components are involved, usually high manufacturing tolerances are set on all the individual components, so that when combined, an unsatisfactory gap appearance may result a later stage.
[0005] To solve this problem, it is possible to form a bearing block in a shell shape (thus quasi as a separate door inner trim), which engages behind the door inner trim towards the vehicle interior. Here only a gap between the actuation lever and the directly visible surrounding bearing block is created, and on account of the shortness of the tolerance chain, the gap appearance here is simple to realise. However with this, it is a problem that a relatively “clumsy” appearance arises which results from the protrusion of the bearing shell into the vehicle interior, and this hinders a harmonic overall appearance. Furthermore it is a problem that the bearing shells need to be manufactured of a relatively strong plastic which is cost-intensive and because of great demands on the surfaces, needs to be additionally painted, and in turn higher costs arise due to this.
[0006] It is of course also possible to shape the complete door inner trim of such a high-strength plastic (such as e.g. polyamide). However even greater manufacturing costs arise on account of this.
[0007] Another solution lies in the fact that due to “rolling” gaps between the actuation lever and the connecting trim, one succeeds in these not being conspicuous, even with uneven gaps. However the problem here is that the geometries of the door trim are very greatly restricted.
BRIEF SUMMARY OF THE INVENTION
[0008] The object of the present invention therefore lies in creating a door for motor vehicles which may be manufactured in an inexpensive manner and which fulfils the high demands with regard to the gap dimensioning.
[0009] A door with the features of claim 1 achieves this object.
[0010] Because of the fact that with a motor vehicle door according to the preamble of claim 1 , the arbor is additionally connected to the trim via fixation bearings, it is easily possible to achieve a uniform gap appearance. This is due to the fact that the tolerance chain is quasi “shortened”, i.e. that an additional direct coupling between the trim and the arbor of the actuation lever is created (without the “detour” via the bearing block). Therefore, it is no longer necessary to demand that all components in a long tolerance chain have high manufacturing and gap tolerances in order as a whole to achieve a harmonic gap appearance. The reduction of the occurring tolerances is thus achieved without a limitation of the tolerance in manufacture.
[0011] Also, it is not necessary to manufacture the trim itself of a particularly stable expensive material. The fixation bearings assume merely the positioning or centering of the actuation lever to the connecting trim. The actual accommodation of force may take place in a conventional manner, e.g. via screw domes on that side of the trim which is distant to the motor interior. In particular with the solution according to the invention, is possible to fit the actuation lever into a trim in a flush manner. No bearing blocks etc. which project into the motor interior are required.
[0012] Advantageous formations of the present invention are specified in the dependent claims.
[0013] One advantageous further formation envisages the trim to be of polypropylene. This is a plastic capable of being manufactured inexpensively and which has a satisfactory surface quality without paint. This is particularly suitable for motor vehicles such as trucks, small buses, etc.
[0014] One further advantageous formation envisages the trim to be of several parts. This trim may e.g. consist of a first part and of a second part both of which comprise a surface directed towards the motor vehicle interior. In this manner it is easily possible to manufacture doors of two colours. The first and second part may e.g. consist in each case of differently coloured plastic and thus it is possible without expensive painting to influence the optical appearance of the door with regard to colour. Here it is particularly advantageous for the first part to be designed as an upper part which forms the inner breast or beltline of the motor vehicle door, and the lower part to be formed by a base carrier which, proceeding from the upper part, continues downwards to the door lower edge. This base carrier may contain openings for loudspeakers or rests, etc.
[0015] A particularly advantageous further formation envisages screw domes or likewise (rivet receivers etc.) being arranged on the second part of the trim, for fastening of the bearing block on the second part with a non-positive fit. Here it is essential that by way of this e.g. screw connection, only a tensioning takes place in order to hold the bearing block, and the actual geometric centering or exact definition of the position is accomplished by the fixation bearing indicated above. For this reason it is significant for these screw domes or likewise to have play in their condition of not being tightened so that depending on the setting of the additional fixation bearing, the screwing accommodating the force may be carried out in the different positions (a mechanical redundancy is avoided by way of this). It is particularly advantageous then on the first part of the trim, thus here e.g. of the window beltline or breast, to attach the fixation bearings for the unambiguous positioning of the arbor with respect to the trim.
[0016] This is also advantageous on assembly, thus the bearing block e.g. is introduced into the first part and positioned by way of this. For this the fixation bearings e.g. may have run-in chamfers. The screwing which is effected after this is however not significant with regard to the tolerance but merely serves for tensioning. It is yet to be emphasised that the fixation bearing ensures the actual centering or fixation or setting of the gap magnitude.
[0017] A further design envisages the bearing block being sunk with respect to the trim towards the vehicle exterior. By way of the fact that the bearing block or the trough for the actuation lever which contains it, into which e.g. an operators hand engages, does not protrude partly to the vehicle interior, this part does not also need to be painted or finished in any other manner in order to achieve demands set on the surface qualities, since the covered trough is practically not visible.
[0018] One advantageous design envisages the bearing block or the actuation lever being of polyamide. This plastic has good strength properties. E.g. the actuation lever may also be painted where there are very high demands on the surface.
[0019] A further advantageous design envisages the fixation bearings being designed as receivers open on one side. These may e.g. be “U” shaped, possibly with run-in chamfers and a locking bulge. By way of this it becomes possible to position the bearing block before it is then screwed to the trim in this position. A fastening of the arbor position in the axial direction is additionally possible.
[0020] Further advantageous designs of the present invention are specified in the remaining dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The invention is hereinafter explained by way of several figures. There are shown in:
[0022] FIG. 1 a view of a cut-out of a motor vehicle door according to the invention, from the motor vehicle interior,
[0023] FIG. 2 a a cross section through the motor vehicle door shown in FIG. 1 ,
[0024] FIG. 2 b a detailed view of a fixation bearing according to the invention,
[0025] FIG. 3 an alternative embodiment with less favourable tolerance conditions.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 shows a motor vehicle door 1 according to the invention which comprises a trim 3 facing towards the passenger space of a motor vehicle. The trim in FIG. 1 is seen from the vehicle interior, and the trim 3 is of two parts. The trim consist of an upper part 3 a as well as of a lower part 3 b which are firmly bonded or welded to one another. The upper part 3 a forms a window breast or beltline towards the window 12 of the motor vehicle. The lower part forms a base carrier of the trim in which rests or a loudspeaker opening not shown in FIG. 1 are incorporated. The trim as a whole is fastened on a door module or a frame of a motor vehicle door. The parts 3 a and 3 b are in each case of unpainted polypropylene. Both parts are coloured with a different colour in that in the trim, a different colouring for the breast or beltline part and the base part results when viewed.
[0027] An actuation lever 5 mounted in an articulated manner is arranged surrounded by the upper part 3 a. This actuation lever in regions forms a gap with the surrounding upper part 3 a; this joint in its upper region is indicated at 7 b and at its lower region at 7 a.
[0028] It is the main aim of the present invention to design this gap over its whole length as uniformly as possible, wherein at the same time a uniform view is to result with as low as possible costs.
[0029] The actuation lever 5 is arranged essentially flush to the trim (see FIGS. 2 a and 3 ), and below the actuation lever a trough belonging to the bearing block 4 is arranged into which an operator's hand may engage in order to grip behind the actuation lever 5 .
[0030] The bearing block as well as the actuation lever 5 are of unpainted or painted polyamide.
[0031] FIG. 2 a shows a cross section according to A-A (see FIG. 1 ) through the motor vehicle door according to the invention. Here a part of the motor vehicle door 1 is to be seen which comprises a trim 3 (consisting of the parts 3 a and 3 b ) towards the passenger space 2 of the motor vehicle. The trim 3 may be connected to the bearing block 4 , e.g. via screws. In the bearing block 4 , the actuation lever 5 is pivotally mounted about a rotation arbor 6 , wherein between the actuation lever 5 and the trim 3 , a gap 7 a and 7 b is given at least in regions. The arbor 6 is additionally connected to the trim via fixation bearings 8 a and 8 b.
[0032] FIG. 2 a is now explained in more detail after this general description. One may easily recognise that the trim 3 consist of the upper part 3 a and the lower part 3 b. The upper part 3 a and the lower part 3 b are e.g. welded to one another in the region 13 . The lower part 3 b comprises screw domes 9 a and 9 b into which screws 14 are screwed. These screws 14 engage behind bores in the bearing block 4 and thus in the firmly screwed condition fix the bearing block 4 on the screw dome 9 a and 9 b. The through-bores in the bearing block 4 have a larger diameter than the shanks of the screws 14 so that when the screws are not tightened, no exact geometric fixing of the bearing block 4 on the trim is given, but rather a coupling “having play”.
[0033] The bearing block 4 comprises a trough 15 which is set back with respect to the motor vehicle interior 2 . As a whole the bearing block 4 is sunk with respect to the trim towards the vehicle exterior, so that this is practically not visible from the interior. An arbor consisting of plastic or metal is mounted in the bearing block 4 via two through-openings, and is pivotally mounted with the actuation lever.
[0034] This arbor 6 is furthermore mounted in fixation bearings 8 a and 8 b. These fixation bearings 8 a and 8 b belong to the upper part 3 a. Here for example it is the case of injection moulded webs of the upper part 3 a.
[0035] The fixation bearings 8 a and 8 b are designed e.g. as “U”-shaped receivers, thus open at one side (see FIG. 2 b ). These, as shown in FIG. 2 b, may have run-in chamfers in the region of the limbs of the “U” and serve for fixing the arbor 6 .
[0036] With the assembly of the subject shown in FIG. 2 a, firstly the upper part 3 a and the lower part 3 b are welded into a finished trim. Then the actuation lever 5 via the arbor 6 is assembled in the bearing block 4 . Then from the rear side of the trim (thus the direction of the reference numeral 10 in FIG. 2 a ) the bearing block 4 is fixed in that the arbor 6 is fixed in the fixation bearings 8 a and 8 b open towards the reference numerals. By way of this fixation, the geometric position of the arbor is exactly defined i.e. the axis is centred in an exact manner. In this position then the screws 14 are screwed through the through-openings of the bearing block 4 into the screw dome 9 a and 9 b and tightened so that a non-positive fitting fixation of the bearing block in the position predefined by the fixation bearing 8 a and 8 b is effected.
[0037] By way of the short “tolerance chain” between the actuation lever 5 as well as the trim 3 (or the upper part 3 a ), it is ensured that the gap 7 a and 7 b runs in a uniform manner also without great manufacturing and gap tolerances. Thus a harmonic appearance of the actuation lever arises in the trim, and this is the case with the gaps as well as for the flush incorporation of the actuation lever with respect to the trim. In FIG. 2 a one may easily see that the actuation lever in the cross-sectional direction perpendicular to the vehicle longitudinal axis terminates essentially flush with the trim.
[0038] Finally a section according to FIG. 3 is shown for purposes of comparison. Here the parts are indicated with the same reference numerals as FIG. 2 a. The bearing block 4 ′ shown in FIG. 3 has an actuation lever 5 mounted via an arbor 6 ′. The screw domes 9 a′ and 9 b′ accommodate screws 14 which are guided through through-openings of the bearing block 4 ′ and engage behind the bearing block 4 ′. The spring domes engage essentially with a positive fit into the through openings of the bearing block 4 ′ so that its geometrical position has already been completely defined by way of this. A securement from detachment is finally effected by way of the screws 14 .
[0039] The design has the disadvantage that the gaps 7 a′ and 7 b′ only have a satisfactory quality with regard to the dimensions when a multitude of components (screw dome 9 a′, 9 b′, bearing block 4 ′, arbor 6 ′, actuation lever 5 ) are machined in a very accurate manner and are also joined according to the directed manner. If errors occur in this relatively “long” tolerance chain this unavoidably leads to deviations in the dimensions with the gaps 7 a′ and 7 b′ which may manifest itself in an unsatisfactory optical appearance or may even lead to jamming of the actuation lever 5 on the trim 3 ′.
[0040] The essential advantage of the design according to FIG. 2 a is the fact that the tolerance chain, by way of the direct coupling via the fixation bearings 8 a or 8 b, is shortened towards the arbor 6 so that an excellent joint appearance arises without an expensive restriction of the tolerances.
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The invention relates to a vehicle door having a lining that faces the passenger compartment of a motor vehicle. The lining can be joined to a bracket inside of which an actuating lever is mounted in a manner that enables it to swivel around a pin. A gap is provided at least in areas between the actuating lever and the lining. In addition, the pin is joined to the lining via fixing bearings.
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This application is a division, of application Ser. No. 945654, filed 12/23/86 now U.S. Pat. No. 4,742,331.
FIELD OF THE INVENTION
This invention relates to circuitry for generating programmable time delays.
BACKGROUND OF THE INVENTION
In modern computer control systems, it is frequently necessary to convert a digital signal (which is used internally in the computer) to a variety of analog signals which are used to directly control or measure the environment. Two conversion devices which are often used in manufacturing systems are digital-to-analog converters (DACs) and analog-to-digital converters (ADCs). These units convert between analog signals generated by the environment and the digital signals used by the computer.
Another, perhaps less widely used, conversion device is a digital-to-time converter. This unit accepts a digital signal and produces a proportional time delay. The delay usually appears as a time difference between two pulses appearing at the output of the device or between a trigger pulse and a pulse appearing at the output of the device. Such programmable time delay circuits are often used in automated test equipment and are used to delay digital signals.
Digital-to-time converters have conventionally been fabricated from discrete semiconductor devices. In such devices, the conversion is often performed by comparing a linearly-increasing voltage or current ramp signal to a threshold voltage or current. In one conventional form of a digital-to-time converter, a fixed threshold voltage is set by a precision voltage reference source and the time delay is generated by comparing the threshold voltage to a ramp with a variable slope. The slope of the ramp is set by the value of the digital word to program the device. In another conventional form of the converter, a ramp with a fixed slope is generated and the time delay is obtained by comparing the ramp voltage to a variable threshold whose level is set in accordance with input digital word.
In either of the above variations, when the value of the ramp voltage equals the value of the threshold voltage a pulse signal is generated. If a pulse signal is generated at the start the ramp signal, the time elapsing between the two pulse signals represents a delay which depends on the value of the digital input word. The starting pulse may also be the trigger pulse which is used to start the ramp signal generation.
It would be convenient to fabricate a digital-to-time converter circuit as a monolithic integrated circuit. Such a device would have many obvious advantages over a discrete-device implementation of the same circuit. For example, the integrated circuit would be smaller, have higher reliability, better performance, a lower power consumption and a lower cost. However, practical problems are associated with the implementation of a digital-to-time device as a monolithic integrated circuit. One of these problems arises from the need to produce a device that is stable with variations in temperature and power supply voltages--a problem common with integrated circuits. The solution to temperature and power supply variation compensation problems generally involves the use of precision reference sources.
The first problem is to obtain a predictable ramp signal. In a digital-to-time converter designed with discrete devices, the internal ramp signal is conventionally generated by charging a capacitor with a stable current generated by placing a precision voltage reference source across a precision resistor. Such a precision voltage source is generally comprised of a voltage reference source, a resistor, and a control amplifier connected in a standard feedback configuration. Once a stable charging current has been established, the voltage across the capacitor provides a stable ramp output.
The second problem is to obtain a stable threshold value. In many prior art circuits, the threshold voltage is generated by a digital-to-analog converter (DAC). In order to assure predictable operation, the DAC voltage must also be referenced and controlled so that variations in the voltage caused by temperature and power supply changes track the temperature and supply-induced changes in the ramp voltage. In a typical prior-art design, the same voltage reference source used to generate the ramp signal is used to drive an additional control amplifier or a current mirror circuit to measure and reflect the ramp current into the DAC so that variations in the threshold voltage track variations in the ramp voltage.
This conventional approach requires the fabrication on the integrated circuit of a voltage reference source and control amplifier or a current mirror (which requires two different bipolar transistor types). In either case, the circuit becomes expensive and more difficult to manufacture.
The problem is additionally complicated because typically the resistor and capacitor used to generate the ramp voltage are external to the integrated circuit so that the user can easily change the ramp slope and, thus, the time constants involved in the circuit. However, the threshold voltage is generally determined by internal integrated circuit component values which may not track the temperature and supply changes in the external ramp components.
Accordingly, it is an object of the present invention to provide a digital-to-time converter which can be easily fabricated as a monolithic integrated circuit.
It is another object of the present invention to provide a digital-to-time converter which does not require the use of an internal voltage reference source and control amplifiers.
It is still another object of the present invention to provide a digital-to-time converter which can be manufactured entirely with transistors of one bipolar type.
It is yet another object of the present invention to provide a digital-to-time converter which is temperature and supply variation compensated to produce a stable output in spite of temperature and power supply variations.
It is still another object of the present invention to provide a digital-to-time converter which can be inexpensively manufactured.
SUMMARY OF THE INVENTION
The foregoing problems are solved and the foregoing objects are achieved in one illustrative embodiment of the invention in which a digital-to-time converter is comprised of a ramp generator circuit and a DAC circuit. The input to the ramp generator circuit and the input to the DAC circuit are connected to a voltage coupling circuit which ensures that the changes in the ramp voltage caused by temperature and power supply variations track changes in the threshold voltage produced by the DAC. Thus, variations in the outputs caused by thermal and power supply changes appear as a common mode signal in both the ramp and threshold voltages. The voltages are compared by a differential comparator which rejects the common mode signal and amplifies the differences to generate the output pulse. The need for precision voltage reference sources, control amplifiers and current mirrors is thereby eliminated.
More particularly, the ramp signal is generated by charging a capacitor with a current controlled by a precision resistor. Both of these components are external to the integrated circuit so that the ramp voltage slope can be easily adjusted.
The DAC operates as a plurality of switched parallel-connected, binary-weighted current sources. The sources can be connected either to the DAC output or shunted to the power supply, based on the digital input word. The current running through the DAC output can be passed through a resistor and used to generate a threshold voltage whose value depends on the value of the digital word. However, the total current running through the DAC is independent of the value of the digital word and is, instead dependent on a circuit network which extends through a reference resistor The voltage appearing across the reference resistor is representative of the thermally-induced changes and power supply variations in the DAC current, and, consequently, the corresponding thermal and power supply-induced changes in the threshold voltage which is generated from the DAC current.
The voltage appearing across the resistor used to generate the ramp voltage is caused to track the voltage appearing across the reference resistor by the voltage coupling circuit. Since the capacitor charging current is determined by the voltage appearing across the ramp resistor, any changes in the DAC current due to temperature and power supply variations will cause a corresponding change in the charging current. Consequently, the thermal and supply-induced changes appear as a common mode signal to the differential output comparator and are rejected. Thus, temperature and supply effects on the operation of the circuit are minimized.
In addition, the circuit values used to set the current in the DAC are chosen so that the DAC current is proportional to absolute temperature (PTAT). With this choice of values internal biasing of the DAC is greatly simplified, eliminating the usual requirements of a control amplifier.
Another feature of the circuit concerns the input circuitry. This circuitry has been designed to reduce reset time, thereby allowing the digital-to-time circuitry to operate at a higher speed.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block schematic diagram of the inventive digital-to-time converter circuit.
FIG. 2 is a detailed electrical schematic diagram of the trigger/reset flip-flop circuitry.
FIG. 3 is a electrical schematic diagram of the ramp generator and current coupling circuitry.
FIG. 4 is a simplified electrical schematic of the current coupling circuit.
FIG. 5 is an electrical schematic diagram of the output comparators.
FIG. 6 is a detailed electrical schematic of the input section of the digital-to-analog converter.
FIG. 7 is an electrical schematic of the conversion section of the digital-to-analog converter.
FIG. 8 is a detailed electrical schematic of the input latch section of the digital-to-analog converter.
FIG. 9 is a section of the wiring for the digital-to-analog converter.
FIG. 10 shows the arrangement of FIGS. 2,3 and 5-9 to form the complete circuit.
FIG. 11 is an equivalent circuit diagram for a level shifting device used in the circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventive digital-to-time converter has a TRIGGER input, a RESET input, a minimum delay output and a programmed delay output. The TRIGGER input accepts a positive-going-edge signal to trigger the circuit. Internal circuitry prevents an erroneous re-triggering until the circuit function has been completed. After the circuit has been triggered, and after a propagation delay, a pulse appears at the minimum delay output. This pulse is used in the same fashion as analog ground in a digital-to-analog converter to reference the zero state (zero time delay in the present circuit). Subsequently, after a programmed time delay depending on the values of the digital input word (on leads B1-B8), a second pulse appears at the programmed delay output. The time elapsing between the two pulses represents the time delay generated by the device. The RESET input is dominant over the TRIGGER input. In the presence of a RESET input the device cannot be triggered and, if already triggered, it resets.
More particularly, as shown in FIG. 1, the device accepts a differential, or single-ended, emitter-coupled-logic (ECL) signal applied to its TRIGGER input 100. The TRIGGER signal on lead 100 is applied to input and ramp start circuitry 106. Upon a rising edge being detected, the ramp start circuitry controls the charging of capacitor 120 which, as will hereinafter be described, generates the ramp voltage used to generate the programmed time interval.
Circuitry 106 also responds to signals on the RESET leads 108, but contrary to the operation of the TRIGGER portion of the circuit, circuit 106 is designed to be sensitive to the level of the RESET signal rather than the signal edges. When a "high" RESET signal is applied to the RESET leads 108, the charging of capacitor 120 is terminated and the circuit is reset regardless of the state of the TRIGGER inputs or the state of the circuit.
When the ramp start circuitry is activated, it removes the base drive signal on lead 114 which is normally applied to transistor 116 (transistor 116, in the quiescent state, is normally "on" and short circuits timing capacitor 120). However, when the ramp start circuitry is activated, it applies a "low[ signal to the base of transistor 116 which turns "off" the transistor. Capacitor 120 then begins charging from VCC, 118, through voltage coupling circuit 122 and resistor 124.
As will be hereinafter described in detail, circuit 106 is designed to accelerate the turn-on of transistor 116 when a reset signal is sensed so that the reset time of the circuit is minimized. Since the reset time is an appreciable part of the overall cycle time, high-speed operation is facilitated.
The voltage across capacitor 120 is compared, by comparator 138, to a minimum delay voltage to generate the minimum delay output. The minimum delay voltage is generated across resistor 117. The voltage appearing across resistor 117 is determined by the voltage coupling circuit 122 which will be described in detail below. In the quiescent state of the circuit, a current source, 127,create an "offset" that maintains the output comparator 138 in an "off" state to avoid an indeterminate state at the output. However, as capacitor 120 charges, the voltage across it quickly exceeds the offset voltage and comparator 138 shifts to a "high" MDO signal indicating a minimum propagation delay through the device. As previously mentioned, the "high" MDO signal can be used as a zero-time reference in a manner similar to the use of analog ground as a zero-voltage reference for a conventional digital-to-analog converter.
The voltage across capacitor 120 increases as the capacitor charges and, eventually, generates a programmed delay output (PDO) signal. The PDO signal on leads 134 is generated by comparator 132 which has inputs 135 which are, in turn, connected to timing capacitor 120 and to a threshold circuit which comprises DAC 128 resistor 119 and current source 127.
As will hereinafter be described in detail, DAC 128 accepts TTL signals representing a digital word on its inputs 130. This digital word is latched into converter 128 by means of a level-sensitive latch signal appearing on lead 131. The DAC effectively appears as a plurality of parallel-connected, binary-weighted current sources 129. In response to the digital word, converter 128 connects these current sources either to supply voltage 118 or resistor 119. The current running through each of the parallel sources is determined by components in the DAC and in voltage coupling circuit 122 so that the total DAC current is independent of the digital word. The portion of the current running through the resistor 119 is determined by the value of the digital word and is also proportional to the total DAC current since it is comprised of the current running through selected ones of the parallel-connected sources. The current running through resistor 119 causes a threshold voltage to develop at point 125, the value of which is dependent on the combination of current sources connected to resistor 119, which combination is, in turn, dependent on the value of the digital word and on the total DAC current.
The total current running through the DAC is determined by internal DAC components, components in voltage coupling circuit 122 and resistor 126. In particular, the DAC current runs through reference resistor 126 to create a reference voltage VA, and, accordingly, the voltage VA is representative of the changes in the DAC current caused by thermal and supply variations. Since the current running through the resistor 119 is proportional to the total DAC current, the threshold voltage appearing across resistor 119 is proportional to the reference voltage VA and variations in the threshold voltage caused by thermal and supply variations are represented by variations in the reference voltage VA.
In accordance with the invention, voltage coupling circuit 122 is arranged to force the voltage, VB, appearing across ramp resistor 124 to be equal to the reference voltage VA. Thus, the charging current to the ramp generating capacitor 120 and the resulting ramp voltage is dependent on the voltage VB, which is equivalent to reference voltage VA. Thus, variations in the internal threshold voltage appearing across resistor 119 appear as corresponding variations in the ramp voltage. Since both the threshold voltage appearing at point 125 and the ramp voltage appearing at point 123 are applied to differential comparator 132, any variations in the voltages due to temperature changes, power supply variations or component variations appears as a common mode signal to differential comparator 132 and are rejected.
Comparator 132 develops an output when the ramp voltage at point 123 reaches the threshold voltage at point 125. At that point, a "high" signal appears on leads 134 which "high" signal indicates the programmed time delay from the occurrence of the MDO signal (or the trigger signal).
As with the circuit that generates the MDO signal, an offset current source 136 is connected to point 125. Current source 136 maintains comparator 132 in its "off" state in the absence of signals from capacitor 120 and converter 128.
FIG. 2 shows a detailed electrical schematic of the TRIGGER/RESET flip-flop and input signal comparator circuitry. As previously mentioned, the TRIGGER/RESET flip-flop is designed so that the TRIGGER input is rising-edge sensitive and the RESET input is level sensitive and dominates over the TRIGGER input. The circuitry is arranged so that either single-ended or differential inputs can be used. In the case of a single-ended input, the unused input is pulled by internal resistors to the emitter-coupled logic (ECL) midpoint voltage (VBB). For example, for single-ended operation of the SET input, resistor R148 pulls the SET* input to the midpoint voltage VBB.
Midpoint voltage VBB is established by transistor Q249. More particularly, the base of transistor Q249 is held at a potential between gorund and the negative supply (VEE) by means of a voltage divider consisting of resistor R138, diodes Q250 and Q251 and resistor R139. The emitter of transistor Q249 thus establishes the ECL midpoint voltage by means of current running through resistor R140. It should be noted that some transistors have a notation "A" next to the transistor symbol. This notation refers to the relative emitter area. Thus, a transistor with a notation of 2A has twice the emitter area of a transistor with the notation "A". An absence of a notation denotes a transistor with an area equivalent to a transistor with a notation of "A".
A "high" signal applied to the SET input triggers the device. This "high" signals is applied to the base of transistor Q409. Transistors Q409 and Q410 are connected in a well-known emitter-coupled differential circuit. In this circuit, the emitters of both transistors are tied to a current source which conducts a predetermined amount of current. More specifically, the current source consists of transistor Q424. The base of transistor Q424 is connected to a voltage source whose output is driven by transistor Q203 (shown in FIG. 4). Consequently, the emitter of transistor Q424 is fixed at a predetermined potential and a predetermined, constant current is drawn through resistor R420 to the negative supply voltage, VEE.
Returning to the emitter-coupled differential pair, Q409 and Q410, in accordance with conventional operation, when transistor Q409 turns "on", it conducts the entire current drawn by the current source. Thus, transistor Q410 is turned "off".
With transistor Q410 turned "off", resistor R407 pulls the base of transistor Q411 "high", turning "on" transistor Q411. Turned-on transistor Q411 applies a "high" signal to the base of transistor Q416, in turn, turning it "on". Transistors Q412, Q413, Q415 and Q416 are connected in a flip-flop configuration and, when transistor Q416 turns "on" it pulls the base of transistor Q413 "low", which, in turn, pulls the base of transistor Q415 "low", turning it "off".
When transistor Q415 turns "off", it allows resistor R408 to pull the base of transistor Q412 "high" and turn "on" transistor Q412, which transistor maintains transistor Q416 in an "on" state.
The base of transistor Q157 is also tied to the base of transistor Q416 so that, when the Q412-Q416 flip-flop is set, transistor Q157 is also turned "on". As will hereinafter be described, the collector of transistor Q157 is connected to the ramp generator circuitry so that ramp generation begins when transistor Q157 is turned "on".
At the time when the Q412-Q416 flip-flop is "set", both transistors Q415 and Q156 (connected in parallel to transistor Q415) are turned "off". When transistor Q156 turns "off", it allows resistor R401 to pull the base of transistor Q401 "high". This latter action sets a flip-flop consisting of transistors Q402, Q403, Q406 and Q407. When the Q402-Q407 flip-flop is "set", it turns Q408 "on" which pulls the base of transistor Q411 "low". Transistor Q411 is thus inhibited, to prevent improper re-triggering of TRIGGER input.
As previously mentioned, a RESET signal applied to the RESET input overrides the signals applied to the TRIGGER inputs. Thus, if a "high" RESET signal is applied to the RESET inputs, the converter circuit cannot be triggered and, if the converter circuit had already been triggered, the circuit is reset.
In accordance with one aspect of the invention, the reset circuitry is designed to rapidly turn off transistor Q157, thus resetting the circuit. This rapid turn off is accomplished by immediately depriving transistor Q157 of collector current upon the occurrence of a RESET signal. Subsequently, the triggering flip-flops are reset to maintain the circuit in a reset condition. More particularly, a "high" signal applied to the RESET input is applied to the base of transistor Q429 turning it "on". Transistors Q428 and Q429 are connected in an emitter-coupled differential pair and, thus, transistor Q428 turns "off" when transistor Q429 turns "on". When transistor Q428 turns "off", it deprives transistor Q157 of collector current (since the current for transistors Q156 and Q157 passes through transistor Q428) and transistor Q157 immediately turns "off" resetting the ramp generation circuitry.
In addition, the "high" RESET signal is applied to the base of transistor Q419 turning it "on". Transistors Q418 and Q419 are also connected in an emitter-coupled differential pair and, thus, transistor Q418 turns "off". This latter action allows resistor R412 to pull the base of transistor Q430 "high", resetting the Q412-Q416 flip-flop and maintaining the circuit in the reset condition. When the Q412-Q416 fil-flop is reset Q408 is also turned "on", which action pulls the base of Q411 "low", in turn, inhibiting trigger pulses from retriggering the system.
The ramp generator and inventive voltage coupling circuit is shown in detail in FIG. 3. The Ramp generator circuit consists of timing capacitor C s and timing resistor R s . The voltage coupling circuit consists of transistors Q174-Q180. Ramp generation begins when the TRIGGER/RESET flip-flop is "set" as previously described. More particularly, when transistor Q157 (FIG. 2) turns "on", the base of transistor Q158 is pulled "low" turning the latter transistor "off". Transistor Q158 normally shorts timing capacitor C s . Therefore, when transistor Q158 turns "off", it allows capacitor C s to begin charging from VCC, through transistors Q164, Q168, resistor R141, Q174, Q178 and timing resistor R s to the supply voltage VEE.
Transistors Q164 and Q168 act as part of a current divider, however, transistors Q174 and Q178 act, as will hereinafter be described, to insure that the timing capacitor charging current tracks variations in the DAC current caused by thermal and supply variations and, accordingly, that the ramp voltage tracks the threshold voltage.
A capacitor, C1, is connected to the base of transistor Q158 to delay the rise of the base voltage of transistor Q158 during reset of the ramp generator when control transistor Q157 (FIG. 2) turns "off". The small delay produced by capacitor C1 is necessary to prevent transistor Q158 from going into saturation as it charges capacitor C s during reset operation. Capacitor C1 thus speeds the ramp reset cycle.
The ramp voltage developed across capacitor C s is applied to the base of transistor Q159 which acts as an emitter follower. From the emitter of transistor Q159 the ramp signal is applied through diode Q265 to point A. The signal at point A is one of the signals which is provided to the output comparator. In order to convert the ramp voltage into a time delay, the ramp voltage is compared to a threshold voltage which is generated by a DAC. As will hereinafter be described, the threshold voltage appears at the base of transistor Q161 and is applied through transistor Q161 (which acts as emitter follower) and diodes Q160 and Q266 to point B. The signal at point B acts is compared to the signal at point A by the output comparator. Since the ramp slope, the initial ramp starting voltage and the threshold voltage are known, a predictable delay can be generated.
More particularly, the threshold voltage is generated by a current drawn through resistor R76 by the DAC. As described in detail below, the DAC converts the value of a digital word into a predetermined current flow through resistance R76 by selectively connecting internal current sources either to resistor R76 or to the power supply. The internal DAC current sources are weighted as binary submultiples of the total DAC current which is independent of the value of the digital word. Accordingly, although the value of the threshold voltage depends on the exact combination of current sources connected to resistor R76, it will always be proportional to the total DAC current. The total DAC current flows from the DAC through the voltage coupling circuit path consisting of transistors Q175 and Q179 and the reference resistor R84 to the supply voltage VEE. Accordingly, the voltage across the reference resistor R84 is proportional to the threshold voltage.
In accordance with another aspect of the invention, the voltage coupling circuit, consisting of transistors Q174-Q179, ensures that the voltage across the ramp generating resistor R.sub. s is equal to the voltage appearing across the reference resistor R84. Thus, the voltage across the ramp generating resistance R s tracks changes in the voltage across the reference resistor R84.
The operation of the voltage coupling circuit can be seen by referring to FIG. 4 which is a simplified diagram of the circuit. In FIG. 4, a simple equation can be written for the voltages around the circuit loop staring at point 400 and proceeding around the loop in the direction of arrows 402.
More particularly, starting at point 400, the path extends through resistor R84, the emitter-base voltage of transistor Q179 the emitter-base voltage of transistor Q177, the emitter-base voltage of transistor Q174, the drop across diode Q175, the base-emitter voltage of transistor Q176, the base-emitter voltage of transistor Q178, the drop across resistor R s , to the negative supply voltage VEE and point 400. Assuming that the threshold current is I t (running in the direction of arrow 404) and the capacitor charging current is I s (running in the direction of arrow 406), writing the equation for this voltage loop gives the following:
-VA+V.sub.be (Q179)+V.sub.be (Q177)+V.sub.be (Q174)-V.sub.be (Q175)-V.sub.be (Q176)-V.sub.be (Q178)+VB=0 (1)
Because transistors Q175 and Q179 are connected in series, with the exception of the base current drawn by transistor Q176, the collector currents of transistors Q175 and Q179 are approximately equal. Since transistor Q176 acts as an emitter follower, if transistor Q176 has a reasonable gain, its base current is small relative to the collector currents of transistors Q175 and Q179 and can be neglected. Thus, to a first-order approximation, the collector currents running through transistors Q175 and Q179 are equal and, consequently, the base-emitter voltages of transistors Q175 and Q179 are approximately equal. Similarly, the base-emitter voltages of transistors Q174 and Q178 are approximately equal and, likewise, the base-emitter voltages of transistors Q176 and Q177. With these equalities, equation (1) above reduces to the following:
-VB+VA=0 (2)
and consequently,
VA=VB (3)
In addition, to a first order approximation, the current I t running in the direction of arrow 404 through the reference resistance R84 also runs either through resistance R76 or directly from the power supply through the DAC. Assuming that a fraction, K, of the DAC current is directed through resistor R76 as determined by the action of the DAC and by the value of the digital word, the threshold voltage at point B (VD) will be proportional to the reference voltage VA.
VA=I.sub.t *R84 (4) and
VD=K*I.sub.t *R76 (5)
thus, eliminating I t ,
VD=K*VA*R76/R84 (6)
Thus, it can be seen that the threshold voltage is, to a first order approximation, proportional to the reference voltage. Since the constant of proportionality depends upon the ratio of two resistor values, if both resistors are diffused and have approximately the same temperature coefficient (TC), the TCs of the resistors cancel out and do not affect the ratio of the voltages VD and VA.
The capacitor charging current is proportional to the voltage VB divided by the value of resistor R s . Since the voltage VB is forced to be equal to the value of the reference voltage VA, the ramp capacitor charging current, and consequently, the ramp voltage, is impressed with the same temperature and power supply variations as the threshold voltage.
Both the ramp voltage signal and the threshold voltage are effectively applied to a differential comparator to generate the programmed delay output. The temperature, supply and base-emitter-voltage induced variations in these voltages are seen as common-mode signals by the output comparator and rejected. Thus, the temperature and supply variations of the programmed delay is, to a first-order approximation, a function only of the TCs of the external timing components R s and C s . In the same manner, power supply variations (in VEE) also appear as a common mode signal to the output comparator and are also rejected.
The equalities in equations (2), (3) (5) and (6) are only first order approximations due to the effect of base currents. In particular, transistors Q178 and Q179 draw a finite base current from the opposite leg of the coupling circuit. In the illustrative circuit, the effect of these base currents has been reduced by the use of emitter followers Q176 and Q177 which reduce the base current draws to a low value.
The proportionality of the voltage VD to the reference voltage VA is further compensated by the addition of a resistance in the base connection of transistor Q174. If this resistance is not inserted and the base of transistor Q174 is connected directly to the collector of transistor Q175 (as shown in FIG. 4), then the current flowing out of the DAC is not completely equivalent to I t because transistor Q174 draws additional base current away. Accordingly, the DAC current will be larger than it should because some current has been added to it. In order to compensate for this effect, a resistance (shown as resistor R81 in FIG. 3 is inserted into the base path of transistor Q174. Since the base of transistor Q174 is fixed relative to the reference voltage VA (by means of V be diode drops of transistors Q179, Q177 and Q174), this resistance has the effect of reducing the voltage at the emitter of Q179 by an amount equal to the base current times the value of the resistor. If the compensating resistor has the same value as reference resistor R84, then the voltage decrease will exactly cancel the effect of the base current.
Another variation that is compensated by the output comparator is the change in the base-emitter voltage of transistor Q158 due to variations in the collector current of transistor Q158. These variations may, for example, be caused by variations in R s which is provided by the user. To compensate for these variations, (referring to FIG. 3) the ramp voltage and the threshold voltage are connected to the output comparator via equivalent paths. These paths consist of Q158, Q159 and Q265 for the ramp signal and Q161, Q160 and Q266 for the threshold signal. Transistors Q165 and Q166 act as current sources, and draw equal currents both of which are proportional to the value of resistor R s . Accordingly, variations in R s appear in both the ramp signal and the threshold signal as common-mode signals and are rejected by the output comparator.
In order to generate a minimum delay out (MDO) signal which does not depend on the value of the digital word, a separate MDO threshold is set by resistor R77 at the base of transistor Q163. This threshold voltage is provided through diodes Q162 and Q267 to point C which is an input to the minimum delay out comparator. The MDO comparator compares the value of the MDO threshold voltage to the value of the ramp signal to generate the MDO signal.
Transistors Q172 and Q173 act as offset current sources. They are used to ensure that the programmed delay output and the MDO comparators remain in a predetermined state in the quiescent state. Transistors Q172 and Q173 draw a sufficient amount of current through resistors R76 and R77, respectively, to place both the MDO comparator and the programmed delay out comparator into "low" output states in the quiescent circuit condition.
The output comparator circuitry for both the programmed delay out signal and the MDO signal are shown in FIG. 5. Both the comparator for the MDO signal and the programmed delay output are identical and, thus, only one circuit will be described in detail.
The programmed delay output (PDO) comparator consists of a first-stage differential input circuit (consisting of transistors Q181-Q186), level shifters Q189 and Q190, a second-stage differential amplifier (transistors Q193 and Q194) and output drivers Q191 and Q192. More particularly, the base of transistor Q186 receives the ramp signal generated from point A in FIG. 3. The base of transistor Q185 receives the threshold signal generated at point B of FIG. 3. Transistors Q185 and Q186 (FIG. 5) form a differential pair which, in turn, drive transistors Q181 and Q182. A small amount of hysteresis is employed in the input stage in order to minimize output comparator propagation delay in various overdrive conditions. The hysteresis is created by drawing small currents through the emitters of transistors Q183 and Q184 by means of transistor Q188. The currents have values such that the second-stage gain times the first-stage hysteresis equals a valid output logic swing.
The output signals on the emitters of transistors Q181 and Q182 are level-shifted by means of devices Q189 and Q190 and their accompanying resistors, R89 and R92. An equivalent circuit for these devices is shown in FIG. 11. The input drives the output transistor 1102 through a Zener diode 1104 which provides the level shift. A resistor 1106 is used to provide bias current for the Zener device.
The level-shifted signals are provided to the base of a differential amplifier consisting of transistors Q193 and Q194 which is used to amplify the output signals. Finally, the output signals are applied to the bases of output drivers Q191 and Q192, respectively, which act as emitter followers to provide output current drive to the output signal leads.
Transistors Q202-Q206 operate as a voltage bias source which provides a predetermined voltage to drive the current sources used in the differential devices. Similarly, transistors Q198-Q201 also provide a voltage reference source for driving the current sources which operate various differential devices.
The DAC used in the inventive circuitry is shown in FIGS. 6-9. The DAC essentially consists of a plurality of eight input circuits (of which one is shown in FIG. 6 and the remaining seven, 700-712, are shown in FIG. 7) a plurality of parallel-connected current sources shown in FIG. 7 and a DAC input latch circuit shown in FIG. 8. FIG. 9 shows additional wiring for connecting FIG. 7 to FIG. 8.
The DAC input circuits are identical and, accordingly, only one is discussed in detail for clarity. The input circuits accept eight standard TTL logic signals on leads designation B1-B8. One bit of the digital input word is applied to each input circuit. For the circuit shown in FIG. 6, the digital signal appears on input lead B1 and is, in turn, applied to the base of transistor Q3. Transistor Q3 acts as an emitter-follower and drives transistor Q4, the emitter of which is connected to the emitter of transistor Q7.
Assuming, for the moment, that transistor Q8 is "on", transistors Q4 and Q7 act as a differential pair. A "high" digital input signal causes transistor Q4 to turn "on". As transistor Q4 turns "on", transistor Q7 turns "off". Transistors Q4 and Q7 control transistors Q1 and Q2 which, in turn, control a current switch consisting of transistors Q14 and Q15. Transistors Q14 and Q15 either connect point D in the threshold circuit (FIG. 3) to the DAC circuit (in the case of a "high" digital input bit) or disconnect point D in the threshold circuit to the DAC circuit (in the case of a "low" digital input bit).
More specifically, transistor Q4, in turning "on", pulls the base of transistor Q1 "low", causing transistor Q1 (which acts as an emitter-follower) to apply a "low" signal to the base of transistor Q14. Transistor Q7, in its "off" state, allows resistor R2 to pull the base of transistor Q2 "high" which action, in turn, applies a "high" signal to the base of transistor Q15. Transistor Q15 thus turns "on" and transistor Q14 turns "off". When transistor Q15 turns "on", it connects the base of transistor Q161 to one of the DAC current sources shown in FIG. 7. Alternatively, when transistor Q14 is "on", it connects VCC to the DAC current source shown in FIG. 7. Consequently, resistor R76 in the threshold circuit is selectively connected to one or more current sources in the DAC circuit by the input circuits depending on the number of "high" bits in the digital word.
Transistors Q8 and Q9 act as a current-steering switch which is used to "latch" the input signal as will hereinafter be described. During digital signal input, transistor Q8 is turned "on", in turn, enabling transistors Q4 and Q7. However, when a DAC latch signal is applied to the circuit (as described below), transistor Q9 turns "on" and transistor Q8 turns "off". When transistor Q8 turns "off", transistors Q4 and Q7 are disabled. However, transistors Q5 and Q6 are turned "on".
Transistors Q5 and Q6 form a flip-flop circuit with transistors Q1 and Q2 which maintains the on-off state of transistors Q1 and Q2 which existed at the time the digital inputs were latched. Thus, if transistor Q1 is "on" at the time when transistor Q9 turns "on", transistor Q5 will also turn "on" which, in turn, holds transistor Q2 in the "off" state. Alternatively, if transistor Q1 is "off" when transistor Q9 turns "on", then transistor Q5 will also be "off", allowing resistor R2 to pull the base of transistor Q2 "high", turning it "on". Transistor Q2, in turning "on", turns "on" transistor Q6, thereby pulling the base of transistor Q1 "low" to holding it in its "off" state. Thus, the inputs digital signals are latched into the input circuits upon the application of a DAC latch signal.
The DAC current sources are shown in FIG. 7 and consist of nine transistors with bases connected in parallel to the signal common terminal. Transistors Q123-Q128 and their associated resistances form a conventional R-2R resistance ladder. Together with transistors Q247-Q122, the effect is to form a plurality of parallel-connected current sources. The currents drawn by the sources are related by binary weights toward each other. For example, the current drawn by transistor Q123 is twice the current drawn by transistor Q124 and so on. The general configuration of this circuit and its operation is well-known.
With the exception of transistors Q247 and Q121, each of the nine transistors drives a switch at its collector, which switch is controlled by one of the latch circuits. Transistors Q247 and Q121 are connected in parallel to reduce the value of their effective emitter resistances to an appropriate value. As previously described, the input circuits are controlled by the digital input word and connect the collectors of the transistors either directly to VCC or to VCC through resistance R76. Accordingly, the total DAC current is independent of the value of the digital word. However, the current running through resistor R76 depends on the settings of the DAC input switches and, thus, the threshold voltage developed across the resistor R76 depends on the value of the digital word.
In a conventional binary-weighted current DAC such as that shown in FIG. 7, it is necessary to maintain strict proportionality between the currents drawn by the current sources. However, each of these currents is produced by a voltage drop across a resistive network and the voltage drop incorporates the base-emitter voltage of the transistor associated with that current source. Since the currents passing through each of the transistors is different, the base-emitter voltages will also be different. These latter differences upset the strict proportionality of the currents drawn by each of the sources. Several prior art arrangements have been used to compensate for this imbalance. Such arrangements include unequal emitter areas of the current source transistors. By appropriately sizing the emitter areas, the base-emitter voltages can be adjusted to compensate for the difference in current magnitudes. Unfortunately, the application of this technique to DACs with more than a few bits requires some of the transistors to have impractically large areas, thus requiring well-known techniques of partitioning. Such techniques are described in U.S. Pat. Nos. 3,978,473 and 4,020,486 assigned to the assignee of the present invention and incorporated herein by reference. Another prior art alternative is to use inter-base resistances which adjust the base currents to compensate for the differences in collector currents of the transistors. Such an arrangement is shown in U.S. Pat. No. 3,940,760 and assigned to the assignee of the present invention and incorporated herein by reference.
Alternatively, it is possible to use a compensation circuit which introduces a compensating voltage at the end of the R-2R resistor network. Such an arrangement modifies the currents in each of the current sources in such a manner that the currents, although modified, remain in binary ratios. The operation of such a compensating circuit is more fully described in U.S. Pat. No. 4,349,811 issued to Paul Brokaw on Sept. 14, 1982 and assigned to the assignee of the present invention. The disclosure of this latter patent is hereby incorporated by reference. As described in this patent, a special compensation circuit is connected to the end of the R-2R chain to provide the proper compensating voltage.
However, in accordance with another aspect of the invention, the special compensation circuit is simplified by passing through the DAC circuit a current which is roughly proportional to absolute temperature (PTAT). In most conventional DAC circuits, the total DAC current is carefully fixed to a precise value. However, in the inventive circuit the total DAC current can be allowed to vary as a function of temperature due to the action of the voltage coupling circuit. Because the voltage coupling circuit causes the ramp voltage to track the threshold voltage regardless of the actual voltage values, the precise value of the DAC current can be allowed to vary and the circuit will still provide temperature compensation as described above.
In accordance with another aspect of the invention, it has been discovered that if the DAC current is PTAT, then the proper compensation as set forth in U.S. Pat. No. 4,349,811 can be provided by placing a single transistor at the end of the current source ladder whose emitter voltage is smaller than the emitter voltage in the current source transistor of the least significant bit by a difference of 2(kT/q)ln 2 volts, where k=Boltzmann's Constant, 1.381 ×10 -23 Joules per degree Kelvin, T=the absolute temperature in degrees Kelvin, q=the elementary charge of 1.602×10 -19 Coulombs, and ln is the natural logarithm. Because the DAC bias current is PTAT, the current in R57 can be maintained at twice the current in R56 over temperature. By well-known formulas this condition can be obtained by providing a compensation transistor having an emitter area of eight times the area of the least-significant bit transistor. Thus transistor Q129, which has an emitter area of eight times transistor Q128, can supply the correct compensating current. A diode provided by transistor Q242 is placed in the collector circuit of transistor Q129 to compensate for the diode introduced by the current steering circuits in the input circuits (the base-emitter of transistors Q14 or Q15 in FIG. 6).
The total current running through the DAC circuit is roughly PTAT because of the way it is generated. In particular, the DAC current results from placing the supply voltage (VEE) of 5.2 volts across four diode voltage drops and various resistors. The four diode voltage drops can be seen by following the circuit starting at signal ground, the base emitter diode of transistor Q247 (FIG. 7), the base-emitter diode of transistors Q174 and Q177 and Q179 (FIG. 3) through resistor R84 to supply voltage VEE. Similarly, four diode drops appear in each of the current source circuits.
If the four diodes and the resistors had 4.88 volts across them, then the resulting current would be substantially PTAT. Since, in the actual circuit, 5.2 volts are placed across the four diode voltage drops and resistors, the DAC current is only roughly PTAT. However, it is sufficiently close that the proper compensation can be obtained by the simple transistor compensation circuit consisting of transistor Q129.
FIG. 8 shows the latching circuitry which is used to latch the digital word bits into the DAC input circuits. In particular, the DAC latch signal is applied to the base of transistor Q229. When a "high" DAC latch signal is applied, transistor Q229 turns "on" and turns "on" transistor Q228 and turns "off" transistor Q227. When transistor Q228 turns "on", it applies a "low" signal, via emitter-follower 240, to level shifter circuit Q226.
Transistor Q226, in turning "on", applies a "low" signal to transistor Q9 in the input circuits (one of which is shown in FIG. 7). As previously mentioned, this "high" signal causes the input circuits to latch the input digital word bits.
Transistors Q232-Q238 are used to provide a voltage reference source which powers the current sources that drive the differential circuits.
In the illustrative embodiment shown in FIGS. 2-9, resistor values are noted next to each resistor. The values are given in ohms with the notation "K" equivalent to a multiplier of 1000. Capacitor values are given in picofarads. The transistors are of standard NPN configuration.
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A current-source ladder digital-to-analog converter is compensated for temperature changes by making the total current running through the converter proportional to absolute temperature and by terminating the parallel transistor chain forming the current source ladder with a transistor whose emitter voltage is greater than the emitter voltage of the least significant bit current source transistor by 2(KT/q)ln 2 volts. The aformentioned voltage difference is achieved by making the emitter area of the termination transistor at least eight times the emitter area of the least significant bit transistor.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image display apparatus such as a head mounted display which is mounted on the head to see a video image.
2. Related Background Art
Recently, image display apparatuses called head mounted displays (HMDS) which are mounted on the heads to see video images projected on display units are used for the purpose of seeing video images or screens of personal computers.
An HMD realizes appreciation of videos and the like anywhere without any influence on ambience. However, since it is mounted on the head, a demand has arisen for a lightweight apparatus with light fitting properties or a portable apparatus easy to detach. In addition, a portable facsimile image display apparatus which aims at seeing a facsimile image, or a portable image display apparatus such as a portable video phone has also been proposed.
As an HMD, an apparatus using a half mirror and concave mirror as an optical system and an LCD panel or a transmission liquid crystal display as a display element, which illuminates the LCD panel with backlight to see an image on the LCD panel is disclosed in Japanese Laid-Open Patent Application No. 8-251510. The present applicant has also proposed an optical system suitable for an HMD in Japanese Laid-Open Patent Application No. 7-104209.
As a portable image display apparatus, a transceiver having a small virtual image display is disclosed in Japanese Laid-Open Patent Application No. 7-235892. A display element and optical system suitable for this apparatus are disclosed in Japanese Laid-Open Patent Application No. 8-327920.
However, since the HMD disclosed in Japanese Laid-Open Patent Application No. 8-251510 uses a half mirror and concave mirror as an optical system, the optical system is large in the back-and-forth direction with respect to the line of sight. In addition, since the electrical circuit is arranged above the optical system, the dimension also becomes larger in the vertical direction to result in poor portability. This degrades the portability and makes it difficult to carry the apparatus in a pocket. Furthermore, since a half mirror is used, no bright screen display is possible.
In Japanese Laid-Open Patent Application No. 7-104209, an apparatus uses a sculptured surface prism to reduce the dimensions of the optical system and obtain light fitting properties. However, much improvement is required to carry the apparatus in a pocket or for portable use as an HMD.
In the portable image display apparatus disclosed in Japanese Laid-Open Patent Application No. 8-327920, since the optical system is formed by overlapping lenses in the direction of line of sight, and the electrical circuit board is arranged in the direction parallel to line of sight, the dimension in the back-and-forth direction becomes large.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an image display apparatus which solves the above-described problems and realizes small dimensions and excellent portability.
Other objects, features, and advantages of the present invention will become apparent from the following description of preferred embodiments in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the first embodiment;
FIG. 2 is a sectional view showing the main part;
FIG. 3 is a sectional view showing the second embodiment;
FIG. 4 is a perspective view showing the third embodiment;
FIG. 5 is a sectional view of the main part;
FIG. 6 is a perspective view showing the fourth embodiment;
FIG. 7 is a perspective view showing a portable video phone of the fifth embodiment;
FIG. 8 is a perspective view showing the sixth embodiment;
FIG. 9 is a perspective view showing the main part; and
FIG. 10 is a perspective view showing the seventh embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 is a perspective view showing an image display apparatus according to the first embodiment. FIG. 2 is a sectional view. This image display apparatus mainly comprises transmission LCD panels 1 L and 1 R for displaying video images for the left and right eyes of a user, respectively, flat tube-type fluorescent backlight units 2 L and 2 R for illuminating the LCD panels 1 L and 1 R, respectively, sculptured surface prisms 3 L and 3 R for enlarging video images on the LCD panels 1 L and 1 R and projecting them onto the left and right eyes, respectively, and an electrical circuit board 4 for controlling the system. These members are compactly accommodated in cover members, i.e., a base cover 5 and lid cover 6 of, e.g., an ABS resin.
The LCD panels 1 L and 1 R and sculptured surface prisms 3 L and 3 R are supported by a holding member 7 formed from, e.g., a polycarbonate resin. The holding member 7 has attachment surfaces 8 L and 8 R for attaching the LCD panels 1 L and 1 R for left and right eyes. The attachment surfaces 8 L and 8 R have openings 9 L and 9 R, respectively. A board attachment boss 10 projects upward between the attachment surfaces 8 L and 8 R.
The LCD panels 1 L and 1 R are positioned such that predetermined relationships hold between the LCD panels 1 L and 1 R and sculptured surface prisms 3 L and 3 R, respectively, the display portions are positioned in the ranges of the openings 9 L and 9 R of the holding member 7 , and the user can obtain a natural view in observation, and fixed on the attachment surfaces 8 L and 8 R of the holding member 7 by bonding or screwing.
A total of four attachment flanges 11 LL and 11 LR, and 11 RL and 11 RR (attachment flanges 11 LR and 11 RR are not shown) are vertically formed at the two ends of the openings 9 L and 9 R on the lower side of the attachment surfaces 8 L and 8 R, respectively. A rib vertically formed between the attachment flanges 11 LR and 11 RL has an attachment hole 12 (not shown).
The sculptured surface prisms 3 L and 3 R are formed from, e.g., an acrylic resin and have optical characteristics as disclosed in Japanese Laid-Open Patent Application No. 7-104209. A total of four attachment flanges 13 LL and 13 LR, and 13 RL and 13 RR (attachment flanges 13 LR and 13 RR are not shown) are formed integrally with the side surfaces of the sculptured surface prisms 3 L and 3 R, respectively. The sculptured surface prisms 3 L and 3 R are positioned and fixed to the holding member 107 by bonding or screwing while making the attachment flanges 13 LL, 13 LR, 13 RL, and 13 RR correspond to the attachment flanges 11 LL, 11 LR, 11 RL, and 11 RR of the holding member 7 , respectively.
The backlight units 2 L and 2 R are fixed on the LCD panels 1 L and 1 R, respectively, via a spacer or the like by a known means such as bonding. The electrical circuit board 4 having a drive circuit is mounted on the backlight units 2 L and 2 R. The backlight units 2 L and 2 R are electrically connected to electrode patterns on the electrical circuit board by soldering.
Electrodes for driving the backlight units 2 L and 2 R are connected to the electrical circuit board 4 through flexible flat cables 14 L and 14 R, respectively. The flexible flat cables 14 L and 14 R are bent, e.g., once with a margin such that the LCD panels 1 L and 1 R can be moved in positioning them.
The electrical circuit board 4 is formed from, e.g., a multilayered glass epoxy board and has an attachment hole 15 at substantially the central portion. The electrical circuit board 4 is fixed to the board attachment boss 10 of the holding member 7 through the attachment hole 15 by a screw. Circuits for displaying video images on the LCD panels 1 L and 1 R, inverter circuits for turning on the backlight units 2 L and 2 R, and power supply circuit are formed on the electrical circuit board 4 . These circuits are connected to a video signal generation means such as a video deck including a video output circuit, signal processing circuit, and power supply circuit through an electrical wire 16 and a connector. The intermediate layer of the electrical circuit board 4 is partially grounded as a shield layer, so a high voltage generated in the inverter circuits is prevented from adversely affecting the video processing circuit as noise.
An attachment boss 17 projects at the center of the base cover 5 as a cover member. Openings 18 L and 18 R for left and right eyes are formed on the left and right sides of the attachment boss 17 . The attachment boss 17 has a screw hole at the center. The holding member 7 is fixed to the base cover 5 by screwing the base cover 5 through the attachment hole 12 of the holding member 7 . A damping member such as a rubber bush is inserted between the attachment hole 12 of the holding member 7 and the attachment boss 17 of the base cover 5 , so that the holding member 7 is prevented from being deformed by an external force applied to the base cover 5 to impede a natural view.
The base cover 5 and lid cover 6 are fixed by bonding or screwing while a bush 19 attached to the electrical wire 16 is sandwiched between a notch 20 of the base cover 5 and a notch 21 of the lid cover 6 to mechanically fix the electrical wire 16 .
The user mounts the image display apparatus with this arrangement on the head and looks in through the openings 18 L and 18 R of the base cover 5 . Video signals from the video output device are output to the LCD panels 1 L and 1 R. Video images on the LCD panels 1 L and 1 R illuminated with the backlight units 2 L and 2 R are enlarged through the sculptured surface prisms 3 L and 3 R and observed by the user.
Since the image display apparatus of this embodiment has an efficient component arrangement: for example, the electrical circuit board 4 is positioned behind the LCD panels 1 L and 1 R, as shown in FIG. 2 . Hence, the apparatus can be made compact. In assembly, the flexible flat cables 14 L and 14 R have slack and are bent at least once. For this reason, even when the LCD panels 1 L and 1 R move in positioning, the holding member 7 can be prevented from being applied with a force and deformed, and the LCD panels 1 L and 1 R can be prevented from shifting to adversely affect the video image. Since the electrical circuit board 4 is fixed to the holding member 7 at only substantially the central portion, the holding member 7 can be prevented from deforming due to the shape and, more particularly, the flatness of the electrical circuit board 4 , so the user can obtain a natural view.
In this embodiment, the inverter circuits for turning on the fluorescent backlight units 2 L and 2 R are also formed on the electrical circuit board 4 . When noise poses a problem, the inverter circuits are preferably formed on another board and arranged behind the backlight units.
FIG. 3 is a sectional view showing the arrangement of the second embodiment. The electrical circuit board of the first embodiment is a hard plate such as a glass epoxy board. In the second embodiment, the electrical circuit board is formed from a flexible printed board and positioned and fixed to a cover member, thereby making the entire apparatus more compact. The basic arrangement is almost the same as in the first embodiment. The same reference numerals as in the first embodiment denote the same parts in the second embodiment.
An electrical circuit board 30 is formed from a flexible printed board using, e.g., a polyimide resin as a base, and electrically connected to LCD panels 1 L and 1 R through flexible flat cables 14 L and 14 R integrated with the LCD panels 1 L and 1 R. Backlight units 2 L and. 2 R are connected and fixed to the electrical circuit board 30 at positions opposing the LCD panels 1 L and 1 R by soldering. On the flat portion of the electrical circuit board 30 , circuits connected to a video signal generation means through an electrical wire 16 to display signals from the video signal generation means on the LCD panels 1 L and 1 R, inverter circuits for turning on the backlight units, and power supply circuit are formed, as in the first embodiment.
The electrical circuit board 30 has four attachment holes 31 LL, 31 LR, 31 RL, and 31 RR (attachment holes 31 RL and 31 RR are not shown). A lid cover 6 as a cover member has, on its inner surface, four attachment dowels 32 LL, 32 LR, 32 RL, and 32 RR (attachment dowels 32 RL and 32 RR are not shown) for positioning and fixing the electrical circuit board 30 . In assembling the apparatus, the attachment dowels 32 LL, 32 LR, 32 RL, and 32 RR are fitted in the attachment holes 31 LL, 31 LR, 31 RL, and 31 RR of the electrical circuit board 30 , respectively, and the electrical circuit board 30 is fixed to the lid cover 6 by screwing or the like.
Since the interval between the attachment dowels 32 LL, 32 LR, 32 RL, and 32 RR having directional components perpendicular to the viewing surface is made smaller than that between the attachment holes 31 LL, 31 LR, 31 RL, and 31 RR of the electrical circuit board 30 by a predetermined amount, the electrical circuit board 30 is fixed to the lid cover 6 by the elasticity of the electrical circuit board 30 formed from a flexible flat cable.
With this arrangement, the user mounts the image display apparatus on the head and looks in through openings 18 L and 18 R of a base cover 5 . Video signals from the video output device are output to the LCD panels 1 L and 1 R. The video images on the LCD panels 1 L and 1 R illuminated with the backlight units 2 L and 2 R are enlarged through sculptured surface prisms 3 L and 3 R and observed by the user.
Since the electrical circuit board 30 in the image display apparatus is set along the inner wall of the lid cover 6 in assembling, the apparatus can be made compact. In addition, since the electrical circuit board 30 is formed from a flexible flat cable, it can be folded to concentrate circuit components of integrated circuits in the space between the LCD panels 1 L and 1 R and between the backlight units 2 L and 2 R for left and right eyes. Hence, the apparatus can be made more compact.
The image display apparatus of this embodiment has no mount portion, and the user holds the image display apparatus with a hand and looks in through the openings 18 L and 18 R of the base cover 5 . However, when the mount mechanism of an HMD is attached to the base cover 5 , the image.display apparatus can also be used as an HMD.
FIG. 4 is a perspective view showing an image display apparatus according to the third embodiment. FIG. 5 is a sectional view. This will be described below although the description is partially the same as in the above embodiments. This image display apparatus mainly comprises transmission LCD panels 101 L and 101 R for displaying video images for the left and right eyes of a user, respectively, backlight units 102 L and 102 R for illuminating the LCD panels 1 L and 1 R, respectively, sculptured surface prisms 103 L and 103 R for enlarging video images on the LCD panels 101 L and 101 R and projecting them onto the left and right eyes, respectively, and an electrical circuit board 104 for controlling the system. These members are compactly accommodated in cover members, i.e., a base cover 5 and lid cover 6 of, e.g., an ABS resin.
The LCD panels 101 L and 101 R and sculptured surface prisms 103 L and 103 R are supported by a holding member 107 formed from, e.g., a polycarbonate resin. For the holding member 107 , attachment surfaces 108 L and 108 R for attaching the LCD panels 101 L and 101 R for left and right eyes are coupled by a vertical surface 109 . The attachment surfaces 108 L and 108 R have openings 10 L and 110 R at their central portions, respectively.
The LCD panels 101 L and 101 R are positioned such that predetermined relationships hold between the LCD panels 101 L and 101 R and sculptured surface prisms 103 L and 103 R, respectively, the display portions are positioned in the ranges of the openings 110 L and 110 R of the holding member 107 , so that the user can obtain a natural view in observation, and the display portions are fixed on the attachment surfaces 108 L and 108 R of the holding member 107 by bonding or screwing.
A total of four attachment flanges 111 LL and 111 LR, and 111 RL and 111 RR (attachment flanges 111 LR and 111 RR are not shown) are vertically formed at two ends of the openings 110 L and 110 R on the lower side of the attachment surfaces 108 L and 108 R, respectively. The vertical surface 109 has an attachment hole 112 and attachment boss 113 at the upper and lower portions, respectively.
The sculptured surface prisms 103 L and 103 R are formed from e.g., an acrylic resin and have optical characteristics as disclosed in Japanese Laid-Open Patent Application No. 7-104209. A total of four attachment flanges 114 LL and 114 LR, and 114 RL and 114 RR (attachment flanges 114 LR and 114 RR are not shown) are formed integrally with the side surfaces of the sculptured surface prisms 103 L and 103 R, respectively. The sculptured surface prisms 103 L and 103 R are positioned and fixed to the holding member 107 by bonding or screwing while making the attachment flanges 114 LL, 114 LR, 114 RL, and 114 RR correspond to the attachment flanges 111 LL, 111 LR, 111 RL, and 111 RR of the holding member 107 , respectively.
Electrodes for driving the LCD panels 101 L and 101 R are connected to the electrical circuit board 104 with drive circuits through flexible flat cables 115 L and 115 R, respectively. Each of the flexible flat cables 115 L and 115 R has, e.g., an S shape bent twice such that the LCD panels 101 L and 101 R can be moved in positioning them.
The electrical circuit board 104 is formed from, e.g., a glass epoxy board and has an attachment hole 116 at substantially the central portion. The electrical circuit board 104 is fixed to the attachment boss 113 of the holding member 107 through the attachment hole 116 by a screw. Circuits for displaying video images on the LCD panels 101 L and 101 R, inverter circuits for turning on the backlight units 102 L and 102 R, and power supply circuit are formed on the electrical circuit board 104 . These circuits are connected to a video signal generation means such as a video deck including a video output circuit, signal processing circuit, and power supply circuit through an electrical wire 117 and a connector.
The backlight units 102 L and 102 R are formed from flat tube-type fluorescent backlight units 118 L and 118 R and inverter circuits 119 L and 119 R, respectively. The backlight units 102 L and 102 R are fixed on the LCD panels 101 L and 101 R via a spacer by a known means such as bonding and connected to the electrical circuits on the electrical circuit board 104 through electrical wires 120 L and 120 R, respectively.
The base cover 105 as a cover member has an attachment boss 121 at the center, and openings 122 L and 122 R for left and right eyes are formed on the left and right sides of the attachment boss 121 . The attachment boss 121 has a screw hole at the center. The holding member 107 is fixed to the base cover 105 by screwing the base cover 105 through the attachment hole 112 of the holding member 107 . A damping member such as a rubber bush is inserted between the attachment hole 112 of the holding member 107 and the attachment boss 121 of the base cover 105 , so that the holding member 107 is prevented from being deformed by an external force applied to the base cover 105 to impede a natural view. The base cover 105 and lid cover 106 are fixed by bonding or screwing while a bush 123 attached to the electrical wire 117 is sandwiched between a notch 124 of the base cover 105 and a notch 125 of the lid cover 106 to mechanically fix the electrical wire 117 .
With this arrangement, video images corresponding to video signals from the video output device are displayed on the LCD panels 101 L and 101 R. The video images on the LCD panels 101 L and 101 R illuminated with the backlight units 118 L and 118 R are enlarged through sculptured surface prisms 103 L and 103 R and observed by the user through the openings 122 L and 122 R of the base cover 105 .
Since the image display apparatus of this embodiment has an efficient component arrangement: for example, the electrical circuit board 104 is positioned behind the sculptured surface prisms 103 L and 103 R, as shown in FIG. 5 . Hence, the apparatus can be made compact. In assembly, the flexible flat cables 115 L and 115 R have slack and are bent at least once. For this reason, even when the LCD panels 101 L and 101 R move in positioning, the holding member 107 can be prevented from being applied with a force and deformed, and the LCD panels 101 L and 101 R can be prevented from shifting to adversely affect the video image. Since the electrical circuit board 104 is fixed to the holding member 107 at only substantially the central portion, the holding member 107 can be prevented from deforming due to the accuracy of the shape and, more particularly, flatness of the electrical circuit board 104 , so the user can obtain a natural view.
In the third embodiment, the inverter circuits 119 L and 119 R are constructed as the backlight units 102 L and 102 R together with the fluorescent backlight units 118 L and 118 R. However, the inverter circuits 119 L and 119 R may be formed on the electrical circuit board 104 . In this case, to prevent noise, the electrical circuit board 104 and the LCD panels 101 L and 101 R are preferably connected by cables different from those for connecting the fluorescent backlight units 118 L and 118 R.
FIG. 6 is a perspective view of an image display apparatus according to the fourth embodiment, which can be applied to a portable video phone or facsimile viewer. This image display apparatus mainly comprises a transmission LCD panel 130 for a single eye, backlight unit 131 , and sculptured surface prism 132 . These members are accommodated in cover members, i.e., a base cover 134 and lid cover 135 together with an electrical circuit board 133 .
A holding member 136 of this embodiment is also formed from, e.g., a polycarbonate resin. The holding member 136 has an opening 137 , LCD attachment surface 138 , attachment holes 139 L and 139 R, and attachment flanges 140 L and 140 R. The sculptured surface prism 132 is the same as in the third embodiment and has left and right attachment screw holes in the surface opposing the LCD panel 130 outside the range where effective light passes through. When screws 141 L and 141 R are driven into the screw holes through the attachment holes 139 L and 139 R of the holding member 136 , the sculptured surface prism 132 is fixed on the lower side of the holding member 136 .
The LCD panel 130 is fixed on the LCD attachment surface 138 of the holding member 136 by bonding or screwing such that a predetermined relationship holds between the LCD panel 130 and sculptured surface prism 132 , and the display portion is positioned within the range of the opening 137 of the holding member 136 . An electrode for driving the LCD panel 130 is connected to the electrical circuit board 133 having an attachment hole 143 , on which the drive circuit is formed, through a flexible flat cable 142 .
The electrical circuit board 133 is connected to a video signal generation means through an electrical wire 144 and connector. The backlight unit 131 is formed from a fluorescent backlight unit 145 and inverter circuit 146 . The backlight unit 131 is fixed to the LCD panel 130 via a spacer by a known means such as bonding, and also connected to the electrical circuit board 133 through an electrical wire 147 .
The base cover 134 has an opening 148 and attachment bosses 149 L and 149 R. The attachment bosses 149 L and 149 R have screw holes at their centers. When screws are driven into the screw holes through the attachment flanges 140 L and 140 R of the holding member 136 , the holding member 136 is fixed to the base cover 134 .
The lid cover 135 has a board attachment boss 150 . When the board attachment boss 150 is inserted into the attachment hole 143 of the electrical circuit board 133 , and a screw is driven into the screw hole of the board attachment boss 150 , the electrical circuit board 133 is fixed to the lid cover 135 . The lid cover 135 is further fixed to the base cover 134 by a known means such as bonding or screwing. At this time, a bush 151 attached to the electrical wire 144 is sandwiched by notches 152 and 153 of the base cover 134 and lid cover 135 .
With this arrangement, a video signal from the video output device is output to the LCD panel 130 . The video image on the LCD panel 130 illuminated with the backlight unit 131 is enlarged through the sculptured surface prism 132 and observed by one eye of the user who is looking from the opening 148 of the base cover 134 . As described above, when the electrical circuit board 133 is fixed to the top case 135 , the holding member 136 can be prevented from being deformed in fixing the electrical circuit board 133 .
FIG. 7 shows the fifth embodiment in which a single-eye image display apparatus is applied to a portable video phone. A visual unit 156 for displaying an image is connected to a portable telephone main body 155 . More specifically, the image display apparatus shown in FIG. 6 is electrically connected to the portable telephone main body 155 and mechanically fixed. In this case, to cope with the personal difference in head shape between users, the visual unit 156 is preferably fixed such that it can pivot with respect to the portable telephone main body 155 at least in the vertical direction of the screen.
FIG. 8 is a perspective view showing the sixth embodiment. FIG. 9 is a sectional view. An electrical circuit board is formed not from a hard board but from a flexible printed board as part of a flexible flat cable to make the entire apparatus more compact, and this arrangement is applied to an HMD.
The image display apparatus of this embodiment comprises transmission LCD panels 160 L and 160 R for left and right eyes, backlight units 161 L and 161 R, and sculptured surface prisms 162 L and 162 R, as in the third embodiment. An electrical circuit board 163 is formed from the same material as that of a flexible flat cable, e.g., a polyimide resin, and integrated with the flexible flat cable. These members are compactly accommodated in cover members, i.e., a base cover 164 and lid cover 165 , as in the third embodiment. The base cover 164 has an HMD mount portion 166 for mounting the HMD on the head of a user.
A holding member 167 of this embodiment is also formed from, e.g., a polycarbonate resin. The front surface of the holding member 167 corresponds to an attachment surface for attaching the LCDs for left and right eyes, and the rear surface corresponds to a flat prism attachment surface for attaching the prisms for left and right eyes. The holding member 167 has openings 168 L and 168 R for left and right eyes. Prism attachment holes 169 LL and 169 LR, and 169 RL and 169 RR are formed on the left and right sides of the openings 168 L and 168 R, respectively. An attachment hole 171 for fixing the holding member 167 to the base cover 164 is formed in a vertical surface 170 at the central portion.
The sculptured surface prisms 162 L and 162 R are formed from, e.g., an acrylic resin and have the same optical characteristics as those of the third embodiment. Attachment surfaces 173 L and 173 R are formed on surfaces of the sculptured surface prisms 162 L and 162 R opposing the LCD panels 160 L and 160 R so as to surround regions 172 L and 172 R where effective light passes through. The attachment surfaces 173 L and 173 R have attachment screw holes 174 LL, 174 LR, 174 RL, and 174 RR, respectively.
The attachment surfaces 173 L and 173 R of the sculptured surface prisms abut against the prism attachment surface of the holding member 167 . When screws 175 LL, 175 LR, 175 RL, and 175 RR (screws 175 RL and 175 RR are not shown) are driven into the screw holes 174 LL, 174 LR, 174 RL, and 174 RR of the sculptured surface prisms 162 L and 162 R through the prism attachment holes 169 LL, 169 LR, 169 RL, and 169 RR, respectively, the sculptured surface prisms 162 L and 162 R are fixed to the holding member 167 . The position of the prism attachment surface is adjusted such that when the attachment surfaces 173 L and 173 R of the sculptured surface prisms 162 L and 162 R abut against the prism attachment surface of the holding member 167 , images on the LCD panels 160 L and 160 R can be seen as if they were separated from the user by, e.g., 2 m.
Also, for the sculptured surface prisms 162 L and 162 R and holding member 167 , a plurality of, e.g., two positioning bosses are formed on the attachment surfaces 173 L and 173 R (attachment surface 173 R is not shown) of the sculptured surface prisms 162 L and 162 R. Positioning holes corresponding to the bosses are formed in the prism attachment surface of the holding member 167 . The bosses are fitted in the positioning holes to position the sculptured surface prisms 162 L and 162 R in a direction perpendicular to the visual axis and fixed.
The electrical circuit board 163 has expanded portions 176 L and 176 R functioning as flexible flat cables. Each of the expanded portions 176 L and 176 R has an S shape bent twice, as shown in FIG. 8, such that the LCD panels 160 L and 160 R can be moved in positioning them.
The electrical circuit board 163 has attachment holes 177 LL, 177 LR, 177 RL, and 177 RR. Circuits for displaying signals from a video signal generation means on the LCD panels 160 L and 160 R, circuits for turning on the backlight units, and power supply circuit are formed on flat portions 178 a and 178 b on the electrical circuit board 163 . The electrical circuit board 163 is connected to the video signal generation means through an electrical wire 179 .
The base cover 164 has openings 180 L and 180 R and attachment boss 181 . The attachment boss 181 is inserted into the attachment hole 171 of the holding member 167 via a damping member such as a rubber bush is inserted, and a screw is driven into the screw hole formed at the center of the attachment boss 181 , thereby fixing the holding member 167 to the base cover 164 .
The lid cover 165 has four dowels 182 LL, 182 LR, 182 RL, and 182 RR (dowels 182 RL and 182 RR are not shown) for positioning and fixing the electrical circuit board 163 . In assembling the apparatus, the dowels 182 LL, 182 LR, 182 RL, and 182 RR are fitted in the four attachment holes 177 LL, 177 LR, 177 RL, and 177 RR of the electrical circuit board 163 , respectively, as shown in FIG. 9, to fix the electrical circuit board 163 to the lid cover 165 .
When the interval between the dowels 182 LL, 182 LR, 182 RL, and 182 RR formed in the vertical direction with respect to the line of sight is made smaller than that between the corresponding holes on the electrical circuit board 163 by a predetermined amount, the electrical circuit board 163 can be fixed to the lid cover 165 by the elastic force generated in the electrical circuit board 163 . The lid cover 165 is fixed to the lid cover 165 by a known means such as bonding or screwing. The electrical wire 179 is fixed while a bush 183 is sandwiched between the notch of the base cover 164 and notch of the lid cover 165 .
The HMD mount portion 166 is attached to the base cover 164 via an HMD mount portion attachment portion 184 . The HMD mount portion 166 comprises a front frame 185 , left and right side frames 186 L and 186 R, front pad 187 , and left and right hinges 188 L and 188 R. In the non-use state, the HMD mount portion 166 can be retracted by folding the left and right side frames 186 L and 186 R at the left and right hinges 188 L and 188 R.
With this arrangement, the user mounts the image display apparatus on the head using the front pad 187 and side frames 186 L and 186 R. Video signals are output from the video output device to the LCD panels 160 L and 160 R. Images on the LCD panels 160 L and 160 R illuminated with the backlight units 161 L and 161 R are enlarged through the sculptured surface prisms 162 L and 162 R and observed by the user through the openings 180 L and 180 R.
As described above, by fixing the sculptured surface prisms 162 L and 162 R to the holding member 167 and fixing the LCD panels 160 L and 160 R to the holding member 167 , dust can be prevented from entering the LCD panels 160 L and 160 R or surfaces of the sculptured surface prisms 162 L and 162 R opposing the LCD panels 160 L and 160 R. When a high optical magnification is set, a gap between the attachment surfaces 173 L and 173 R of the sculptured surface prisms 162 L and 162 R and holding member 167 , a gap between the LCD attachment surface 174 of the holding member 167 and LCD panels 160 L and 160 R, or a gap at a portion between the holding member 167 for fixing the LCD panels 160 L and 160 R and LCD panels 160 L and 160 R, which is not associated with display, is filled with a filler. In this case, small gaps formed depending on the surface states of components can be filled. For this reason, dust can be prevented from entering the gaps or being seen by the user when he/she looks at an image.
Since the electrical circuit board 163 shown in FIG. 9 is set along the inner wall of the lid cover 165 in assembling, the image display apparatus can be made compact. In addition, when the board and flat cables are laid out such that tall electrical components such as integrated circuits are positioned in the space between the sculptured surface prisms 162 L and 162 R, the apparatus can be made more compact.
FIG. 10 is a perspective view showing an image display apparatus according to the seventh embodiment. This image display apparatus mainly comprises transmission LCD panels 201 L and 201 R for displaying video images for the left and right eyes of a user, backlight units 202 L and 202 R for illuminating the LCD panels 201 L and 201 R, respectively, sculptured surface prisms 203 L and 203 R for enlarging video images on the LCD panels 201 L and 201 R and projecting them to left and right eyes, respectively, and an electrical circuit board 204 for controlling the system. These members are compactly accommodated in cover members, i.e., a base cover 205 and lid cover 206 formed from, e.g., an ABS resin.
The LCD panels 201 L and 201 R and sculptured surface prisms 203 L and 203 R are supported by a holding member 207 formed from, e.g., a polycarbonate resin. For the holding member 207 , attachment surfaces 208 L and 208 R for attaching the LCD panels 201 L and 201 R for left and right eyes are coupled by a vertical surface 209 . The attachment surfaces 208 L and 208 R have openings 210 L and 210 R at their central portions.
The LCD panels 201 L and 201 R are positioned such that predetermined relationships hold between the LCD panels 201 L and 201 R and sculptured surface prisms 203 L and 203 R, respectively, the display portions are positioned in the ranges of the openings 210 L and 210 R of the holding member 207 , and the user can obtain a natural view in observation, and fixed on the attachment surfaces 208 L and 208 R of the holding member 207 by bonding or screwing.
A total of four attachment flanges 211 LL and 211 LR, and 211 RL and 211 RR (attachment flanges 211 LR and 211 RR are not shown) are vertically formed at two ends of the openings 210 L and 210 R on the lower side of the attachment surfaces 208 L and 208 R, respectively. The vertical surface 209 has an attachment hole 212 .
The sculptured surface prisms 203 L and 203 R are formed from, e.g., an acrylic resin and has optical characteristics as disclosed in Japanese Laid-Open Patent Application No. 7-104209. A total of four attachment flanges 213 LL and 213 LR, and 213 RL and 213 RR (attachment flanges 213 LR and 213 RR are not shown) are formed integrally with the side surfaces of the sculptured surface prisms 203 L and 203 R, respectively. The sculptured surface prisms 203 L and 203 R are positioned and fixed to the holding member 207 by bonding or screwing while making the attachment flanges 213 LL, 213 LR, 213 RL, and 213 RR correspond to t he attachment flanges 211 LL, 211 LR, 211 RL, and 211 RR of the holding member 207 , respectively.
Electrodes for driving the LCD panels 201 L and 201 R are connected to the electrical circuit board 204 with drive circuits through flexible flat cables 214 L and 214 R, respectively. Each of the flexible flat cables 214 L and 214 R is bent and connected to the electrical circuit board 204 fixed on one side of the holding member 207 .
The electrical circuit board 204 is formed from, e.g., a glass epoxy board and has an attachment hole 215 . The electrical circuit board 204 is fixed to an attachment boss 217 of the holding member 207 through the attachment hole 215 by a screw 216 . Circuits for displaying video images on the LCD panels 201 L and 201 R, circuits for turning on the backlight units 202 L and 202 R, and power supply circuit are formed on the electrical circuit board 204 . These circuits are connected to a video signal generation means such as a video deck including a video output circuit, signal processing circuit, and power supply circuit through an electrical wire 218 and a connector.
The backlight units 202 L and 202 R comprise flat tube-type fluorescent backlight units 219 L and 219 R and inverter circuits 220 L and 220 R, respectively. The backlight units 202 L and 202 R are fixed on the LCD panels 201 L and 201 R via a spacer by a known means such as bonding and connected to the electrical circuits on the electrical circuit board 204 through electrical wires 221 L and 221 R, respectively.
The base cover 205 as a cover member has an attachment boss 222 at the center, and openings 223 L and 223 R for left and right eyes are formed on the left and right sides of the attachment boss 222 . The attachment boss 222 has a screw hole at the center. The holding member 207 is fixed to the base cover 205 by screwing the base cover 205 through the attachment hole 212 of the holding member 207 . A damping member such as a rubber bush is inserted between the attachment hole 212 of the holding member 207 and the attachment boss 222 of the base cover 205 , so that the holding member 207 is prevented from being deformed by an external force applied to the base cover 205 to impede a natural view. The base cover 205 and lid cover 206 are fixed by bonding or screwing while a bush 224 attached to the electrical wire 218 is sandwiched between a notch 225 of the base cover 205 and a notch 225 of the lid cover 206 .
With this arrangement, video images corresponding to video signals from the video output device are displayed on the LCD panels 201 L and 201 R. The video images on the LCD panels 201 L and 201 R illuminated with the backlight units 219 L and 219 R are enlarged through sculptured surface prisms 203 L and 203 R and observed by the user through the openings 223 L and 223 R of the base cover 205 .
Since the component arrangement is efficient: for example, the electrical circuit board 204 is positioned on one side of the sculptured surface prisms 203 L and 203 R. Hence, the apparatus can be made compact. In assembly, the LCD panels 201 L and 201 R and electrical circuit board 204 are separated by the flexible flat cables 214 L and 214 R. For this reason, even when the LCD panels 201 L and 201 R move in positioning, the holding member 207 can be prevented from being applied with a force and deformed, and the LCD panels 201 L and 201 R can be prevented from shifting to adversely affect the video image. Since the electrical circuit board 204 is fixed to the side surface of the holding member 207 , the holding member 207 can be prevented from deforming due to the shape and, more particularly, flatness of the electrical circuit board 204 , so the user can obtain a natural view.
In this embodiment, the inverter circuits 220 L and 220 R are constructed as the backlight units 202 L and 202 R together with the fluorescent backlight units 219 L and 219 R. However, the inverter circuits 220 L and 220 R may be formed on the electrical circuit board 204 . In this case, to prevent noise, the electrical circuit board 204 and the LCD panels 201 L and 201 R are preferably connected by cables different from those for connecting the fluorescent backlight units 219 L and 219 R.
In addition, in this embodiment, one electrical circuit board 204 having circuits for displaying video images on the left and right LCD panels 201 L and 201 R is disposed on one side of the image display apparatus. However, two electrical circuit boards 204 may be arranged on the left and right sides, respectively. Especially, when the scale of the electrical circuit board 204 is large, this arrangement can be employed to improve the portability of the image display apparatus.
In the seventh embodiment, fitting properties as an HMD have not been mentioned. When a mount unit as disclosed in Japanese Patent Application No. 10-14972 by the present applicant is attached to the base cover 205 , a compact apparatus as an HMD excellent in portability can be obtained.
In the image display apparatus of each of above embodiments, sculptured surface prisms are used as an optical system, an electrical circuit board is arranged on one side of the sculptured surface prisms, and the electrical circuit board and display elements are connected through flexible flat cables. With this arrangement, a compact apparatus excellent in portability can be realized.
When sculptured surface prisms for left and right eyes are used, an electrical circuit board is arranged on one side of the sculptured surface prisms, and the electrical circuit board and display elements for left and right eyes are connected through flexible flat cables, the visual axis can be prevented from shifting in the vertical direction due to bend of the flexible flat cables in assembling to adversely affect the optical condition. Hence, a safety, comfortable, and natural binocular can be realized.
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An image display apparatus includes a display element for displaying a video image, a backlight source for illuminating the display element, and a sculptured surface prism for guiding light from the display element. The sculptured surface prism enlarges the video image on the display element and presents the video image to an observer. The display element and the sculptured surface prism are supported by a holding member. An electrical circuit board is provided to drive the display element. The electrical circuit board and the display element are electrically connected. The electrical circuit board is arranged behind the display element, behind the sculptured surface prism when viewed from the observer, or on one side of the sculptured surface prism when viewed by the observer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved exchanger and a method for achieving heat transfer between solid particles contained or circulating in an enclosure and the external environment.
The present invention also relates to the use of the exchanger in the circulating loop of the solid particles in a circulating bed boiler.
2. Description of the Prior Art
The prior art devices are cumbersome and generally have, for equal volume, lower performances than those obtained by the device and process of the invention.
In U.S. Pat. No. 3,087,253, a device is proposed which requires a large exchange surface for there is no recirculation of the solid particles between the central enclosure and the rest of the device.
The prior art may be illustrated by the following patents: EP-A-0095427, EP-A-0006307, EP-A-0033713, EP-A-0093063, FR-A-2261497, FR-A-11 28881, GB-A-1577717, GB-A-1299264, GB-A-1248544, US-A-2842101, US-A-35650022, US-A-4404755, US-A-4538549, US-A-2759710, as well as by the article entitled "Les technologies de combustion en lit fluidise" by R. DUMON published by A.I.M. Association des Ingenieurs Electriciens from the Montefiore Institute, on the occasion of the eighth session of the international, modern electric power station study days, held at Liege Oct. 26-30, 1981.
SUMMARY OF THE INVENTION
The exchanger of the present invention provides, more particularly, a great flexibility of heat transfers between solid particles and the external environment without for all that modifying the flow rate of the solid particles. The exchanger of the present invention has the following advantages:
great compactness linked with excellent heat exchange coefficients in the fluidized beds,
a faculty of adjusting the exchange power required which may be obtained by considerable compartmentation or by using compartments of different sizes,
homogeneity of the temperature in the fluidized bed even when it is fed with considerable amounts of solids, because of the presence of deflectors.
When it is used in a circulating bed boiler, the exchanger of the present invention allows greater simplicity of the whole of the external exchange and recirculation device with in particular a single point of reinjection of the ashes, great flexibility in use linked to the existence of two levers for controlling the powers exchanged as will be discussed more fully hereinbelow.
Thus, the present invention provides an improved exchanger allowing the transfer of heat energy between, more particularly, solid particles and the environment external to the exchanger, with the exchanger comprising inlet and outlet orifices for the particles. This exchanger comprises a main enclosure communicating with the inlet and outlet orifices, with the enclosure comprising fluidizing gas supply means and several auxiliary compartments, each of them comprising at least one orifice allowing the transfer of solid particles from the main enclosure to the auxiliary compartment concerned, at least one orifice allowing solid particles to be transferred from the auxiliary compartment to the main enclosure and means for supplying this compartment with fluidizing gas, these means allowing the solid particles to circulate in said compartment and means for extracting said heat energy.
This exchanger is also characterized in that one at least of said compartments comprises a device for controlling the flow rate of the fluidizing gas passing through said compartment.
The device for controlling the flow rate of the fluidizing gas may comprise a means adapted for all or nothing operation.
The exchanger of the invention may comprise a first and a second cylindrical casing, several side walls, a first and second plate, these two plates defining with said first casing a closed space in which said second cylindrical casing is housed, with the side walls extending between the cylindrical casings so as to define said auxiliary compartments.
The internal space defined by the second casing defines the main enclosure.
The second casing may comprise at least one orifice for admitting solid particles into one of the compartments; this admission orifice may comprise at least one deflector.
The first plate may comprise the fluidization gas supply means and the second cylindrical casing extending substantially from the first plate may stop before reaching the second plate, thus forming a free space between the edge of this casing and the second plate. This free space will serve as outlet orifice for the solid particles.
The exchanger of the present invention may comprise a first cylindrical casing containing a second cylindrical casing, at least one intermediate casing contained in the space defined by said first and second casings, a first and a second plate defining a closed space with the first casing. The internal space defined by the second casing defines the main enclosure and the annular spaces defined by the different cylindrical casings define the auxiliary compartments.
The energy extraction means may be coiled tubing.
Side walls may be situated between the annular spaces thus defining additional compartments.
The exchanger of the present invention may be advantageously used in a circulating bed boiler comprising a reactor and a separator.
The present invention also provides a method for controlling the heat transfer between solid particles contained in an enclosure and the external environment. This method is characterized in that the enclosure is divided into several zones and in tht the fluidization air supply of at least one of these zones is controlled separately.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood and its advantages will be clearer from reading the following description of particular examples which are in no wise limitative, and which are illustrated by the accompanying drawings in which:
FIG. 1 is a partially schematic view of one embodiment of a heat exchanger constructed in accordance with the present invention;
FIG. 1A is a cross-sectional view taken along the line A--A in FIG. 1
FIG. 2 is a partially schematic view of another embodiment of a heat exchanger constructed in accordance with the present invention;
FIG. 2A is a cross-sectional view taken along the line A--A in FIG. 2;
FIG. 3 is a schematic view illustrating an integration of the heat exchanger of the present invention into a circulating bed boiler; and
FIG. 4 is a graphical illustration of operating curves.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings where like reference numerals are used throughout the various views to designate like parts and, more particularly, to FIG. 1, according to this figure, a heat exchanger constructed in accordance with the present invention comprises a main enclosure defined by a cylindrical casing 2.
As shown most clearly in FIG. 1A, auxiliary compartments 3a, 3b, 3c, 3d, 3e, etc . . . are defined by side walls 4a to 4f and an external cylindrical casing 6.
Each auxiliary compartment comprises heat energy transfer means such as exchanger tubes 5 in which a heat carrying fluid may flow. It should be noted that these heat transfer means may either bring heat energy to the solid particles or, on the contrary, remove heat therefrom.
In the case of the embodiment shown in FIG. 1, the solid particles 7 penetrate into the main enclosure 1 through the orifice 8 formed n the plate, or cap 9 which closes the exchanger at its upper part, while letting tubes 5 pass therethrough.
The solid particles 7 leave again through the orifice 10 formed in plate 11, or bottom, which closes the exchanger at its lower part. Of course, without departing from the present invention, the orifices for introducing and removing solid particles may be located at other positions.
In FIG. 1, the bottom 11 of the exchanger comprises the fluidization grids 12a, 12e and 13 of the auxiliary compartments 3a and 3e and of the main compartment 1, respectively.
The arrows shown at the lower part of FIG. 1 symbolize the fluidization gas.
The cylindrical casing 2 is completed at its lower part by a truncated cone shaped metal sheet 14 which comprises orifices 15 allowing solid particles to penetrate into the different auxiliary compartments. These orifices 15 may be advantageously provided with deflectors 16.
The cylindrical casing 2 does not extend as far as cap 9 and stops before so as to leave a free space 1b for the circulation of the solid particles 7, by overflow.
In FIG. 1, the auxiliary compartments have the form of a right prism whose base has the shape of an annular disk sector.
Still within the scope of the present invention, compartments of other forms may be provided.
In the embodiment of FIG. 2, the heat exchanger of this new embodiment is defined by a first cylindrical external casing 20 and comprises a main enclosure 21 defined by a second cylindrical casing 17.
The annular space between the first cylindrical casing 20 and the second cylindrical casing 17 comprises intermediate cylindrical casings 19 and 18. Thus, as shown in FIG. 2a three auxiliary compartments 22a, 22b and 22c are defined.
The exchanger of FIG. 2 comprises a cap 23 in which is provided an orifice 24 for admitting solid particles and a bottom 25 equipped with an orifice 28 for discharging the solid particles and fluidization means 26a, 26b and 26c for the auxiliary compartments and fluidization means 26d for the main enclosure.
The heat energy transfer means are formed from coiled exchanger tubes 27a, 27b, 27c in the different auxiliary compartments.
Of course, still within the scope of the present invention, the annular compartments 27a, 27b and 27c may comprise side walls creating subcompartments; in this case, the exchanger tube may not be completely coiled around the cylindrical casings.
The different ways in which the cylindrical casings may be fixed in the exchanger will not be described in this text, since these techniques are well known to a man skilled in the art.
As shown in FIG. 3, the exchanger of the present invention is inserted between the cyclone 30 and the device for reinjecting ashes into the reactor 31. It allows the particles captured by the cyclone 30 to be fluidized and a part of their perceptible heat to be removed therefrom by means of vaporizer tubes immersed in the bed. The heat exchange coefficients in this medium are very high, in particular if they are compared with those obtained with devices having mobile beds or particles shower beds. The powers exchanged per unit of tube surface are three to six times higher than those obtained with non fluidized exchangers.
The exchanger has the advantage of being able to be fed continuously with the captured ashes and to withstand very high recirculation flow rates.
The vaporizer tubes are placed in auxiliary compartments separated from each other and in communication with a main enclosure. This latter feeds the auxiliary compartments with hot solids. The exchange of solids between the main enclosure and the auxiliary compartments is facilitated by the presence of deflectors 16 which induce intense circulation currents and by using differenciated fluidization air distributors which cause greater ventilation within the auxiliary compartments. With this configuration the temperature throughout the whole of the exchanger may be held constant even when the exchanger has very considerable amounts of solids passing therethrough.
The power of the installation may be modulated by adjusting the temperature or the exchange surface in contact with the fluidized medium. With constant solid particle temperature and constant exchange surface, the temperature of the fluidized bed increases with the solid flow rate. So, controlling the solid flow rate through the exchanger is a means of controlling the thermal power. In the majority of cases, a flexibility of the order of two may be hoped for.
The power may also be reduced by defluidizing some of the auxiliary compartments: the exchanger tubes are then plunged in a fixed bed for which the exchange coefficients are ten to twenty times lower than those of the compartments. This technique corresponds then to neutralizing a part of the exchange surface.
Defluidization of one compartment is achieved by cutting off the air supplying the distributor. Each fluidization caisson may be equipped with an all or nothing valve. The number of compartments is determined as a function of the flexibility required of the exchanger.
Through defluidization, a flexibility of one to ten may be expected and by combining defluidization and control of the temperature of the solids, the overall flexibility of the exchanger is from one to twenty if the supply of fluidization air to the auxiliary compartment is of the all or nothing type. The power variations of the exchanger will therefore be all the more flexible the larger the number of these compartments.
In FIG. 3, the whole of the solids flowing in the loop pass through the exchanger 29, and the reinjection device, which may be of L valve type 32, is the only one. This configuration, like any configuration using an external exchanger, assumes that the flow of solids which escape the cyclones still remains less than the elementary flow of non combustible materials. Since this situation is not necessarily acquired in all cases, it is desirable to provide a device for reinjecting solids captured by the boiler from smoke, even by filters.
In normal operation, i.e. without solid impoverishment of the circulation loop, two tapping devices allow the overall inventory and the grain size of the charge to be checked. The tapping point 33, situated at the base of the reactor, allows the large particles to be removed, and tapping point 34, situated under the external exchanger 19, allows the fine particles to be removed.
The operator of installations similar to the one shown in FIG. 3 has two parameters available for varying the power exchanged:
the recycling rate,
the fluidization or defluidization of the compartments of the external exchanger 29.
This allows the operation of the boiler to be better optimized for all its operating ratings.
As a first approximation and for a reactor operating at a temperature of 850° C., the powers exchanged have the followingrelationships.
Internal exchanger E 1 situated in the reactor,
P.sub.1 =h.sub.1 ·S.sub.1 (850-T.sub.t).
External exchanger E 2
P.sub.2 =h.sub.2 ·S.sub.2 (T.sub.r -T.sub.t)
where
T t : tube skin temperature in degrees Celsius,
T r : recycling temperature in degrees Celsius,
h i : heat exchange coefficient of the exchanger i,
S i : exchange surface of the exchanger i.
Any action on the recycling flow results in modifying the exchange coefficient h 1 , but also T r as a heat test carried out on the external exchanger shows:
Q.sub.E C.sub.ps ·(850-T.sub.o)=h.sub.2 ·S.sub.2 ·(T.sub.r -T.sub.t)+Q.sub.S ·C.sub.ps ·(T.sub.r -T.sub.o)
with
Q E : mass flow rate of incoming solids,
C ps : specific heat of the solids,
Q S : mass flow rate of outgoing solids,
T o : reference temperature.
Under stable operating conditions, the incoming and outgoing flow rates are equal (Q E =Q S ). ##EQU1##
The power exchanged by the external exchanger is therefore ##EQU2##
It increases with the solid flow rate Q S to reach the maximum value
P.sub.2 ∞=h.sub.2 ·S.sub.2 (850-T.sub.t)
An example of application is given hereafter:
The desired distribution of powers is the following:
Internal exchanger: 3.53 MW
External exchanger: 3.72 MW
Boiler on smoke: 7.21 MW.
The essential element in dimensioning the exchange surfaces is the determination of the recirculation rates under nominal operating conditions and reduced operating conditions.
Bases of calculation:
nominal operation:
Recirculation rate: 50
Circulating flow rate: 215 t/h
Exchange coefficient in the reactor: 135 W/m 2 .K
reduced operation 1 (no defluidization of the external exchanger):
Recirculation rate: 10
Circulation flow rate: 21.5 t/h
Exchange coefficient in the reactor: 70 W/m 2 .K
reduced operation 2 (complete defluidization of the external exchanger);
Recirculation rate: 5.4
Circulation flow rate: 5.0 t/h
Exchange coefficient in the reactor: 60 W/m 2 .K
The exchange coefficient in the external exchanger is assumed constant and equal to 300 W/m 2 .K.
From these elements, E 1 and E 2 can be dimensioned.
Exchanger E 1 : S 1 =43.5 m 2 with ΔT of 600° C.
Exchanger E 2 =T 2 =785° C.
S 2 =23 m 2 with a ΔT of 535° C.
In reduced operation 1, the exchanged powers are:
Exchanger E 1 : P 1 =1.83 MW
Exchanger E 2 : T 2 =522° C. P 2 =1.88 MW
Flexibility achieved: 2
In reduced operation 2, the exchanged powers are:
Exchanger E 1 : P 1 =1.57 MW
Exchanger E 2 : P 2 =0
Flexibility achieved: 4.6
FIG. 4, graphically depicts the possibilities of adjustment due to the integration of an external exchanger of the present invention in a circulating bed boiler loop. In FIG. 4, the abscissa is the recirculation rate T, equal to the circulation flow rate of the solids divided by the flow rate of fuel fed into the boiler, and the ordinate is the total power P taken off from solids in such a loop divided by the nominal power taken off from solids.
The external exchanger 10 comprises compartments of equal sizes.
Curves 35 to 43 correspond to bringing into operation one, then two, then three compartments up to the total number of such compartments.
Still within the scope of the present invention, the different compartments may have different shapes and a different arrangement from those shown in the present description, particularly if the compartments are aligned.
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The present invention provides an exchanger and a method for achieving heat transfer between solid particles contained in an enclosure and the external environment.
The device comprises a main enclosure and several auxiliary compartments separate from each other and at least one of said compartments comprises its own fluidization means.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to an adjustable hinge system for use with oversize insulated doors used for commercial walk-in refrigerators and freezers. More specifically, this hinge system is capable of lateral adjustment of the spatial relationship of the door to the frame in order to correct any misalignment of door position in relation to the frame that has occurred through continued opening and closing of the door. Further, any misalignment is corrected by the easy and simple rotation of a cam located within the hinge strap which is accessible from the surface of the hinge so that complete disassembly of the hinge is not required.
[0002] Over the years there have been many attempts at adjusting commercial refrigerator and freezer doors using a variety of mechanisms to accomplish lateral movement for adjustment of the misalignment of the door to the frame. One recent example is U.S. Pat. No. 7,870,642 [Finkelstein, et al.] that describes an anti-sag hinge with a lateral adjustment feature. The anti-sag hinge is divided into two components, a mounting flange attached to the door jamb or frame and a strap assembly mounted to the door and pivotally attached to the mounting flange. The strap assembly has a plurality of slotted or elongated holes for mounting to the door with an adjustment bracket mounted atop the strap with the same number of circular holes generally aligned with the elongated holes of the strap. Extending between the strap and the adjustment bracket are paired flanges connected by a threaded adjustment screw that is capable of inward or outward movement causing relative movement between the strap and the door within the range of the elongated holes. The adjustment bracket remains in fixed position relative to the door with the movement of the door relative to the strap causing a lateral adjustment of the door to the frame or jamb with the turning of the adjustment screw. A similar structure is noted in U.S. Pat. No. 7,584,523 [Finkelstein, et al.] although the focus of this patent is the partial removal of the mounting flange assembly with the removal of the upper barrel portion of the hinge.
[0003] Another earlier method for re-aligning doors to the cabinet frame is described in U.S. Pat. No. 7,055,214 [Finkelstein]. This anti-sag hinge is described as having a mounting flange for attachment to the jamb or frame of a cabinet and a strap assembly for attachment to an associated door. Onto the back side of the strap assembly, between that assembly and the door, is attached an adjustment plate that mates with the underside of the strap assembly by a series of serrated edges arrayed along the opposing surfaces of the strap assembly and the adjustment plate. By loosening the mounting screws and manually relocating the adjustment plate and the underside of the strap assembly from a first mating serration to a second mating serration the door can be laterally adjusted to correct any misalignment from use or wear. As above, a similar apparatus is described in U.S. Pat. No. 6,374,458 [Finkelstein]. In this patent the apparatus is described as having a recess in the underside of the strap assembly to cover and capture the adjustment plate with opposing surfaces having raised surface ridges for locking the strap assembly and the adjustment plate together at predetermined locations. For adjustment, the screws holding the strap assembly and the adjustment plate together are loosened and the two cooperating elements are laterally moved to a different desired position and the screws tightened to re-align the door to the jamb or cabinet frame.
[0004] Another recent commercial walk-in refrigerator/freezer door adjustment apparatus is described in U.S. Patent Application Publication No. US 2006/0032145 A1 [Manders, et al.] In this publication an adjustment screw is accessed from the door edge closest to the hinge and acts against an adjustment plate in the hollow of the door causing the movement of the hinge strap relative to its position against the door to correct misalignment. Another horizontally adjustable hinge is described in U.S. Pat. No. 8,720,008 [Dodge] that provides an adjustment bracket attached to the outer surface of the door which is enveloped in a recess in a strap assembly placed atop the bracket. A slot is machined into the end of the strap assembly closest to the pivot point of the hinge base and an adjustment screw is inserted through the slot such that the head of the screw abuts the outer surface of the strap assembly. The threaded end of the adjustment screw is threadedly coupled to an upstanding flange on the adjustment bracket so that rotational motion of the adjustment screw causes the strap assembly to move relative to the adjustment bracket achieving horizontal adjustment of the door to the frame.
[0005] In the devices discussed above the mechanism for realigning the door has been, for the most part, a threaded screw operating on or through some form of adjustment plate with counterforce against the strap assembly and door. The other devices have been manually relocatable strap assemblies to mate with plates mounted to the doors to achieve repositioning and alignment. These devices are cumbersome to use, may have insufficient force to accomplish the task without external assistance, and may require more than one person to accomplish the re-alignment task.
[0006] There have been other attempts at positioning and realignment of doors using different instrumentalities. At least one earlier device utilized a cam-like apparatus to achieve similar positioning and realignment of doors to associated frames. One such device is described in
[0007] U.S. Pat. No. 2,700,789 [Cornwell] for a hinge system between a standard wooden door and its frame in the door opening. A disk having an elongated slot for mating with an outwardly extending stud from a surface mounted adjustment plate on the door could be manually repositioned over the mounting plate of the hinge to adjust the lateral and vertical position of the door relative to the frame and hinge leaf mounted to the frame. The described apparatus required shimming of the door in order to reposition the elements of the adjustment apparatus properly with a retightening of all elements in the new position before removing the shims. This earlier device was also cumbersome to use and required external elements to properly position the door.
[0008] The present invention eliminates the earlier problems of weight of the door versus size of the adjustment mechanism, or the complexity of manually adjusting the door using shims to achieve the proper realignment before tightening the mounting screws to retain the door in the new position. One should not be persuaded that the shimming of old has been overcome with newer hinge systems as it is still utilized today with some of the hinge systems described above. Counterbalancing a heavy door may be required for realignment if the adjustment mechanism is not of sufficient size to overcome the weight of the door to achieve proper repositioning. The Dodge '008 patent attempted to address this problem by significantly increasing the size of the threaded adjustment screw shaft and thickness of the flange of the adjustment bracket to overcome the significant force of the weight of the door and the gravitational force exerted on the door forcing the door outward and downward away from the hinge base. The Finkelstein '642 patent, with a lighter weight screw and associated threaded flange, did not perform as intended in repeated testing to overcome the significant forces exerted against the adjustment screw and flange with the bending of the flange of the adjustment bracket away from its intended straight-line perpendicularity reducing the effectiveness in the realignment of the heavy door.
[0009] It is, therefore, an object of the present invention to provide an apparatus that overcomes the significant weight forces of the door to achieve realignment of the door with the jamb or cabinet frame. It is another object of the present invention to provide an apparatus that accomplishes the realignment task without significantly altering the mechanical structure of the hinge system or the exterior of the hinge. It is a still further object of the present invention to provide an apparatus that can accomplish the task of repositioning or realigning the door by a single technician.
[0010] It is yet a further object of the invention to provide an apparatus that fits entirely within the unaltered exterior structure of the hinge system and is hidden from view so as to negate any potential for the collection of dirt or other unwanted materials or organisms onto or in the hinge system rendering the hinge system unfit for use in the food storage and service industries. It is also an object of the present invention to provide an apparatus that is simple to use and readily reacts to minimal necessary force from external adjustment.
[0011] Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
[0012] A laterally adjustable hinge system for a walk-in refrigerator or freezer is described comprising a hinge base for mounting to the frame of a door opening and an operationally associated hinge strap extending outward into the door opening and attaching to the door for providing rotational motion of the door about the hinge base. An adjustment bracket for accomplishing lateral displacement of the hinge strap against the door is mounted to the door by a plurality of fasteners and housed within a cooperating recess on the underside of the hinge strap. The adjustment bracket is releasably fastened to the hinge strap by a plurality of fasteners and has a centrally located elongated aperture extending across the bracket for housing an eccentric cam mounted to the shaft of an adjustment bolt extending outward through a cooperating aperture in the hinge strap to expose the adjustment bolt head for manipulation by an adjustment tool. In this fashion the rotational motion of the adjustment bolt head by the adjustment tool causes the cam to move within the elongated aperture about the rotational center of the adjustment bolt causing lateral motion of the hinge strap versus the adjustment bracket for realignment of the door to the frame. The eccentric cam has a flat portion along its perimeter such that when the flat portion comes into abutting contact with a sidewall of the elongated cam aperture this contact indicates that maximum rotation in a clockwise or counterclockwise direction has been accomplished and further indicates that a maximum adjustment point has been reached.
[0013] The laterally adjustable hinge system may be further described such that the releasable fasteners for holding the adjustment bracket to the hinge strap extend through the outer surface of the hinge strap and through a like number of elongated slots in the adjustment bracket mating with a like number of nuts that are held within recesses along the underside of the elongated slots capable of capturing and retaining the nuts, but preventing rotational motion thereof such that loosening and tightening of the fasteners for the hinge strap are independent of the fastening of the adjustment bracket to the door. The adjustment bolt is held in position within the eccentric cam by a C-shaped fastener on the underside of the cam so that rotational motion of the adjustment bolt is directly translated to the cam. The cooperating aperture in the hinge strap has a counterbore for retaining the shaft of the adjustment bolt centered within the aperture to maintain uniform access to the adjustment bolt head for an adjustment tool such that the counterbore acts as a central pivot point for the cam for use in adjusting any misalignment of the door to the frame. The laterally adjustable hinge system is further described as having a cap for overlying and covering the adjustment bolt and cooperating aperture in said hinge strap.
[0014] The laterally adjustable hinge system may be further described for a left-hand oriented hinge system such that the rotational motion of the adjustment bolt in the clockwise direction will cause the adjustment bracket and door to move leftward relative to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket. Likewise, the rotational motion of the adjustment bolt in the counterclockwise direction causes the adjustment bracket and door to move rightward relative to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. For right-hand oriented hinge system the rotational motion of the adjustment bolt in the clockwise direction will cause the adjustment bracket and door to move rightward relative to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. Likewise, the rotational motion of the adjustment bolt in the counterclockwise direction causes the adjustment bracket and door to move leftward relative to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket.
[0015] The invention also includes a method for laterally adjusting a hinge system for a walk-in refrigerator or freezer for realignment of the door to the frame. The method includes providing a hinge base for mounting to the frame of a door opening and an operationally associated hinge strap extending outward into the door opening and attaching to the door for providing rotational motion of the door about the hinge base and providing an adjustment bracket for accomplishing lateral displacement of the hinge strap against the door mounted to the door by a plurality of fasteners with the adjustment bracket housed entirely within a cooperating recess on the underside of the hinge strap. The adjustment bracket is releasably fastened to the hinge strap by a plurality of fasteners.
[0016] The method also includes the providing of a centrally located elongated aperture extending across the adjustment bracket for housing an eccentric cam mounted to the shaft of an adjustment bolt extending outward through a cooperating aperture in the hinge strap to expose the adjustment bolt head for manipulation by an adjustment tool. To obtain a realignment of the door and frame, the invention also includes loosening the hinge strap adjustment bracket fasteners and rotating the adjustment bolt by the adjustment tool that will cause the cam to move within the elongated aperture of the adjustment bracket about the rotational center of the adjustment bolt resulting in lateral motion of the hinge strap versus the adjustment bracket to obtain a realigned position of the door to the frame. The method also includes providing a means to prevent excessive rotational movement of the eccentric cam by providing a flat portion along the periphery of the cam indicating a maximum lateral adjustment point has been reached as a flat portion of the cam comes into contact with a sidewall of the elongated aperture. Finally, the method also includes tightening the hinge strap adjustment bracket fasteners to maintain the realigned position of the door to the frame.
[0017] The method for laterally adjusting a hinge system further includes the providing of a cap for overlying and covering said adjustment bolt and cooperating aperture in said hinge strap.
[0018] When the method is used for laterally adjusting a left-hand oriented hinge system, where the rotational motion of the adjustment bolt is in the clockwise direction, the adjustment bracket and door will move leftward in relation to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket. Where the rotational motion of the adjustment bolt is in the counter clockwise direction, the adjustment bracket and door will move rightward in relation to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. When the method is used for laterally adjusting a right-hand oriented hinge system, where the rotational motion of the adjustment bolt is in the clockwise direction, the adjustment bracket and door will move rightward in relation to the hinge strap and the hinge strap leftward versus the position of the adjustment bracket. Where the rotational motion of the adjustment bolt is in the counterclockwise direction, the adjustment bracket and door will move leftward in relation to the hinge strap and the hinge strap rightward versus the position of the adjustment bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
[0020] FIG. 1 is an exploded perspective view of a left-hand hinge system having the adjustment for lateral displacement of the present invention.
[0021] FIG. 2 is a plan view of the hinge plate or adjustment bracket of the present invention shown mounted in a left-hand hinge orientation with the cam at a central neutral adjustment position.
[0022] FIG. 3 is a plan view of the adjustment bracket of the present invention with the cam at an adjustment position causing the rightward shifting of the hinge strap in relation to the adjustment bracket.
[0023] FIG. 3A is a plan view of the adjustment bracket of the present invention with the cam at the rightmost adjustment position with the flat of the cam against the sidewall of the cooperating cam pathway indicating such position causing the rightmost shifting of the hinge strap in relation to the adjustment bracket.
[0024] FIG. 4 is a plan view of the adjustment bracket of the present invention with its mounting in a left-hand hinge orientation with the cam at an adjustment position causing the leftward shifting of the hinge strap in relation to the adjustment bracket.
[0025] FIG. 4A is a plan view of the adjustment bracket of the present invention with the cam at the leftmost adjustment position with the flat of the cam against the sidewall of the cooperating cam pathway indicating such position causing the leftmost shifting of the hinge strap in relation to the adjustment bracket.
[0026] FIG. 5 is a plan view of the bottom side of the adjustment bracket of the present invention showing the elongated slots and underside of the cam in a central neutral position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
[0028] Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1 an exploded view of the laterally adjustable left-hand oriented hinge system 10 of the present invention. Starting at the left, there is a hinge base or mount 12 which is adapted to be securely attached to the frame of a walk-in refrigerator or freezer with three bolts that extend through the countersunk holes 14 in the hinge base and into the frame of the refrigerator or freezer. There is also a hinge blade or strap 16 which is also adapted to be securely attached to the door of a walk-in refrigerator or freezer with three threaded bolts or fasteners 18 that extend through the countersunk holes 20 in the hinge blade or strap 16 and mate with a like number of similarly threaded nuts 22 that are housed in elongated recesses 24 on the underside of an adjustment bracket 30 , the side juxtaposed against the exterior of the door. See, FIG. 5 . The adjustment bracket 30 fits within a recess on the underside of hinge strap 16 such that it is entirely hidden from external view. Adjustment bracket 30 is adapted to be securely attached to the door of a walk-in refrigerator or freezer by a series of threaded bolts or fasteners 32 that extend through a similar number of countersunk holes 34 in the adjustment bracket and into the door fixedly attaching the adjustment bracket 30 with the attached hinge strap 16 to the door. Prior to attaching the adjustment bracket 30 to the door, the nuts 22 are positioned within the elongated slots 24 that are only wide enough to accommodate the width of the nuts 22 . This allows the nuts 22 to be recessed within the adjustment bracket 30 and prevents the nuts 22 from rotational motion when the hinge strap attachment fasteners 18 are being loosened or tightened.
[0029] Referring again to FIG. 1 , the hinge base 12 is rotatably coupled to the hinge strap 16 with a hinge pin 40 . Hinge pin 40 extends through a female cam 42 and a male cam 44 that cooperates with the female cam, and is attached to flange 46 which is a portion of the hinge base 12 and provides support for the hinge blade or strap 16 . The exterior surface of the female cam 42 is six-sided and mates with a like aperture 43 located in the proximal end of the hinge strap 16 preventing any rotational motion of the female cam 42 within the hinge strap 16 . The hexagonal shapes of the cam 42 and aperture 43 may also be four-sided, eight-sided, or any parallel-sided geometric figure retaining a significant surface at each angular junction to prevent rotation of the cam 42 within the aperture 43 . A spring (not shown) acting in compression may be positioned within the female cam 42 to cause a downward force against the male cam 44 which action will urge the hinge blade 16 to swing the door to a closed position relative to the hinge base 12 . A cap 48 is located on the top of the hinge blade 16 and covers the top of the hexagonal aperture 43 housing the female cam 42 and hinge pin 40 .
[0030] The adjustment bracket 30 has a centrally located elongated aperture 36 extending across the short dimension of the bracket 30 for housing and providing a pathway for an eccentric cam 50 that is mounted to the shaft of adjustment bolt 52 . The bolt 52 is held in position by a C-shaped washer or C-clip 54 on the underside of the cam 50 and extends outward from the adjustment bracket 30 a predetermined distance to extend through a cooperating aperture 56 in the hinge strap 16 . The adjustment bolt 52 is housed within the cam 50 by a flattened side of the bolt shaft aligned with a D-shaped hole through the cam 50 , or by cutting a channel in the shaft of the bolt 52 creating a U-shape or keyway that will mate with a like U-shape cut through the cam 50 , both well-known practices in the art, or by any other similar means that enables the exact tracking of rotational motion of the adjustment bolt 52 by the cam 50 . The C-shaped washer or C-clip 54 will not inhibit the rotational motion of the bolt 52 but will retain the adjustment bolt in a full contact position within the eccentric cam 50 . The head of the adjustment bolt 52 may have a head that mates with a flat blade or Phillips screwdriver, a square or hexagonal nut driver, or a recessed hexagonal or other geometric shape for cooperating with an Allen or other geometrically shaped wrench.
[0031] The cooperating aperture 56 in the hinge strap 16 has a lower centering collar or counterbore 57 for retaining the shaft of bolt 52 centered within the aperture 56 to maintain uniform access to the bolt head for an adjustment tool. The centering collar or counterbore 57 also acts as the central pivot point for the cam 50 for use in adjusting any misalignment of the door to the frame. Covering the cooperating aperture 56 in the hinge strap 16 is a removable cover 58 that snaps in place over the adjustment bolt 52 providing a clean look to the external surface of the hinge strap 16 and preventing debris or other materials from entering the aperture 56 that might impair proper operation of the door adjustment cam 50 .
[0032] Referring now to FIGS. 3-5 , the operation of the door adjustment cam 50 and its effect on the realignment of the door can be described as follows. With reference to FIG. 2 , the adjustment bracket 30 is depicted generally in a median or neutral position approximately midway between the maximum left and right deflections. In the position shown, at the bottom of the elongated aperture or cam pathway 36 extending through the adjustment bracket 30 , the cam 50 may be either in a fully downward position, or alternatively in a fully upward position at the top of the cam pathway within the elongated aperture 36 , such that the door is presumed aligned as originally installed. The pivot point, or rotational center point, for the cam 50 is the shaft of the adjustment bolt 52 that, with the adjustment bracket 30 mounted to the door and the hinge strap 16 mounted to the adjustment bracket 30 , provides the pivotal positioning for the cam 50 with the assistance of the centering collar or counterbore 57 of the cooperating aperture 56 in the hinge strap 16 .
[0033] In FIG. 3 the cam 50 is shown partially rotated to the left from the position shown in FIG. 2 . The shaft of the adjustment bolt 52 has acted as the rotational center for the cam 50 causing the hinge strap 16 to move rightward in relation to the adjustment bracket as shown by the rightward displacement of the attachment fasteners 18 that extend between the hinge strap 16 and the adjustment bracket 30 within the elongated slots 24 . If this action is accomplished on the bottom hinge of the two hinges on a left-side hung door, then the door will move inward toward the left side frame, causing the distal bottom edge of the door to move away from the right side of the opening of the frame. If the action is accomplished on the top hinge of the two hinges on a left-side hung door, the top of the door will move inward and upward slightly correcting any rubbing along the bottom of the door frame. FIG. 3A shows the farthest point that the lateral adjustment apparatus can accomplish by placing the flat 51 of the cam 50 against a sidewall of the elongated aperture or cam pathway 36 such that the hinge strap 16 has moved to the farthest right adjustment point. Continuing to rotate the cam 50 beyond the physical indication point of farthest rightward adjustment by the cam flat 51 abutting against the sidewall of the aperture 36 will not continue any further rightward adjustment, but will allow the adjustable hinge 10 to return toward a neutral position.
[0034] In FIG. 4 the cam 50 is shown partially rotated to the right from the position shown in FIG. 2 . The shaft of the adjustment bolt 52 has acted as the rotational center for the cam 50 causing the hinge strap 16 to move leftward in relation to the adjustment bracket as shown by the leftward displacement of the attachment fasteners 18 that extend between the hinge strap 16 and the adjustment bracket 30 within the elongated slots 24 . If this action is accomplished on the bottom hinge of the two hinges on a left-side hung door, then the door will move outward away from the left side frame, lifting the distal bottom edge of the door eliminating a perceived drag of the door against the step of the frame. If the action is accomplished on the top hinge of the two hinges on a left-side hung door, the top of the door will move outward and downward slightly correcting any rubbing along the top of the door frame. FIG. 4A shows the farthest point that the lateral adjustment apparatus can accomplish by placing the flat 51 of the cam 50 against a sidewall of the elongated aperture or cam pathway 36 such that the hinge strap 16 has moved to the farthest left adjustment point. Continuing to rotate the cam 50 beyond the physical indication point of farthest leftward adjustment by the cam flat 51 abutting against the sidewall of the aperture 36 will not continue any further leftward adjustment, but will allow the adjustable hinge 10 to return toward a neutral position.
[0035] In regard to the cam 50 , there are two neutral positions where the cam 50 is positioned at its downward most position or at its uppermost position. These positions are equivalent to the points on a circle at 0° and 180° of a full rotation of the cam 50 . For the left-hand hinge system described, the equivalent position of 270° (as shown in FIG. 3A ) will be the farthest rightward adjustment available for the hinge strap 16 resulting in the repositioning of the door to the frame described above. Concurrently, the position of 90° (as shown in FIG. 4A ) will be the farthest leftward adjustment available for the hinge strap 16 resulting in the repositioning of the door to the frame also described above. These farthest adjustment points are indicated to the person adjusting the hinge/door alignment by the flat 51 of cam 50 fully contacting the sidewall of the aperture or cam pathway 36 . If the cam 50 passes the 90° and 270° positions, once again approaching a neutral position at either 0° or 180°, the extent of the lateral movement of the door relative to the frame lessens as the cam 50 approaches one of its neutral positions. In the case of right-hand oriented hinge systems, the lateral movement of the hinge strap 16 to the adjustment bracket 30 , and the door repositioning relative to the frame, is reversed from the lateral movement and positioning described above.
[0036] In practice, once all of the components are in place and the door is operational, for adjustment of any misalignment of the door, the following steps are to be performed. First, the removable cover 58 is popped out of the aperture 56 exposing the adjustment bolt 52 . Next, the attachment fasteners 18 are loosened permitting a desired opposite direction relational movement between the adjustment bracket 30 and the hinge strap 16 . An adjustment tool is placed over the adjustment bolt 52 and the appropriate clockwise or counterclockwise rotational motion is performed such that the door reacts to the desired rotational movement of the cam 50 . The farthest adjustment point is indicated when the cam flat 51 of the cam 50 comes into contact with the sidewall of cam aperture or pathway 36 such that the force required to move the cam away from the farthest adjustment point is slightly increased and the technician realizes that the maximum adjustment point was reached. Once the repositioning of the door is accomplished and the door is considered to be realigned for ease of motion and door closure, the attachment screws 18 are retightened maintaining the adjustment bracket 30 and hinge strap 16 in the adjusted position and the cover 58 is snapped back into position within the aperture 56 covering the adjustment bolt 52 . All of the foregoing can be accomplished while the door remains in the closed position. The adjustment of the door can also be done without the need for a second technician or the use of shims for maintaining the door in a desired position while the adjustment elements are reconfigured to retain that door in the newly desired position.
[0037] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein.
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A laterally adjustable hinge system for use on an insulated door of a commercial refrigerator or freezer including a hinge base and associated position adjustable strap relative to the door. The lateral adjustment is accomplished by rotational movement of an eccentric cam located in an adjustment bracket housed within the hinge strap attached directly to the door. The hinge strap is adjustably attached to the adjustment bracket and capable of lateral relational motion controlled by the position of the cam. Cam rotation is controlled by an adjustment bolt extending outward and through the hinge strap protected by a removable cover with a maximum lateral adjustment indicator in the form of a flat portion on the perimeter of the cam such that contact with the sidewall of the cam aperture by the cam flat indicates maximum lateral adjustment in the desired direction has been reached.
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I, claim priority filing date of Apr. 6, 2004 of provisional Application No. 60/560,003
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX
Not Applicable
BACKGROUND FIELD OF INVENTION
Personal use and flapper failure of common tank type toilets used in households in the United States
REFERENCES CITED U.S. PATENT DOCUMENTS
“The present invention relates to the fill valve of ordinary toilets with holding tanks or reservoirs, more specifically to improve and expand the scope and function of the toilet fill valve addressing the issues of water shut off, water conservation and preservation, water damage prevention, anti-siphon and back flow prevention.”
DISCUSSION OF PRIOR ART
Toilet systems, of the reservoir tank type generally installed in American homes, are connected to the potable water supply. The average American home has at least one of these toilets, each of which uses approximately one and one half to three and a half gallons, or more, of water per flush, depending on the age of the toilet.
Generally, toilet fill valves are made with a float mechanism causing the valve to open when the toilet is flushed as the water leaves the tank and to close once the float is lifted by the water when flush valve closes and the tank or reservoir becomes full.
Typically these toilet fill valves work fairly well but have several drawbacks that lead to wasting of water, over flow and leaks. These drawbacks result in a myriad of problems from wells running out of water, dirt being introduced into the water lines from low water levels in shallow wells, and septic system failure, to high water and sewage bills for those on public water supply and sewage systems to water damage to the floor of a bathroom, and ceilings and walls of a downstairs room.
To address these issues manufacturers and inventors began to develop other types of toilet fill valves such as the “Toilet Tank Water Flow Shutoff Apparatus For Preventing Leakage And Overflow, U.S. Pat. No. 5,524,299 of Dalfino, which uses tilting trays to control water level and shutoff of the water supply. Though this device can effectively cause shut off, it tends to have many external moving parts subject to mechanical failure and also uses most of the toilet tank area and servicing as well as installation require more intensive labor and increased expense.
A quite different approach is taken with the Revised Automatic Water Shut Off For Stuck Open Flush Valves In Toilet Water Tanks, U.S. Pat. No. 5,440,765 of Weir, which utilizes a two cylinder system to force the float upwards to shut off the water supply should a continuous flow or wasting of water occur. Similar to the above is the Toilet Bowl Automatic Flow Shut Off and Water Saver Device, U.S. Pat. No. 4,901,377 of Weir, that accomplishes the same results with a bellows assembly that lifts the float when the tank remains empty for a period of time beyond that of normal flushing. Both of the foregoing devices utilize a large portion of the toilet tank area to the right of the flapper valve causing access to the flapper to be flanked on all sides and tends to limit service space for repairs, causing repairs to be costly and labor intensive.
Addressing the issues of conservation, the Water Conserving Toilet Flush Control, U.S. Pat. No. 5,031,254 of Rise, is a device that addresses preventing the wasting of water achieved by limiting the lifting action of the flapper and restricting or preventing automatic operation of flushing. Relatively similar in operation the Water Conserving Toilet Flapper Valve Control, U.S. Pat. No. 5,185,891 of Rise, which in effect limit's the height that the flapper can be lifted achieving the same results as the prior invention of Rise when the flush lever is activated. Though both Rise controls address stopping automatic function of the flapper and limiting the flappers movement they do not address wasting of water when the flapper becomes defective by means of blowout, tear or just ordinary wear of the seal, the results which could lead to a continuous loss of water to the sewer or overflow and water damage.
Fill valves designed to save water such as the Toilet Water Preservation Device U.S. Pat. No. 5,230,104 of Ocampo, tend to use the flow of wasting water redirecting it to a secondary float device that in turn lifts the primary float device. This device though it appears to be quite functional also renders much the same results as the Weir devices utilizing or cluttering tank space hindering and causing labor intensive costly service when repairing or replacing the flapper or primary float valve. The secondary float fill valve is also still subject to fail in much the same way as the primary float fill valve.
Adaptations to fill valves such as the Shut-off Device For The Float Valve Assembly Of A Toilet, U.S. Pat. No. 5,752,281 of Conner, designed so that the rotation of the lever arm causes the float valve assembly to rotate to a stop position and stop the flow of water to the toilet tank in the event that the float fails to raise up for any known reason appears as an entirely different approach. While this system would effectively shut off the flow of water it is possible that with the rotating movement of the float assembly, it could eventually cause leakage and overflow from wear due to excessive movement.
Most of these devices work fairly well shutting off the water, while addressing anti-siphoning of water but do not adequately address back flow prevention, wasting of water if the float fails to be elevated by the water or lack thereof, and or over flow of the bowl or a leaky gasket between tank and bowl. Recently developed toilet fill valves address one or more of these problems. One of the more recent toilet fill valves the FlowManager™ AquaOne Technologies, Inc., addresses most of these problems, incorporates the use of electronic water sensors that detect leaks and overflow. The major drawbacks of such devices are that they require regular and periodical battery maintenance and replacement as well as regular cleaning of the sensor devices that appear as necessary clutter and are actually in the way of cleaning the bowl and or the floor. Additionally, the cleaning of the sensors and the chemicals used, both cleansers and antibacterial toilet additives can cause premature failure. Although the sensor in the bowl will effectively stop overflow of the bowl or bowl in households with children who might lose a toy or otherwise plug the bowl, a floor sensor could present a problem with flushing where bath water is accidentally splashed on it or if a child accidentally misses the bowl and wets the sensor. Electronic valve systems such as the above generally utilize a normally open solenoid valve so the batteries will last a long time if the valve is not triggered shut by a sensor, however if the valve is triggered shut in the case of a flapper leak the batteries would not last very long which would in short time lead to water running to the sewer or worse yet water damage if the bowl was plugged.
Addressing the issues of toilet tank fill and flush problems and wasting of water with control devices has made significant progress in the Positive Shut-off, Metered Water Control System For Flush Tanks, U.S. Pat. No. 4,916,762, by Shaw. This device utilizes the flow of water to turn a vaned water wheel. A worm gear attached to the water wheel drives a spur gear which in turn rotates a second spur and worm gear. The worm gear of the secondary or intermediate gear assembly then engages a spur gear seated in a ratchet and cam assembly. The cam of the ratchet cam assembly controls both opening and closing of a stopper. The cam is ratcheted to the start position by a lever connected to the flush lever of the toilet to cause the stopper to dislodge from its seat when the toilet is flushed to allow water to pass or flow driving the water wheel which causes the cam to turn and reseat the stopper after the desired amount of water has been metered through the system. Although this device is impressive it has the possibility of lockup of the drive system if there is no particle screen at the inlet to stop foreign particles that can cause premature wear and lodging within the gears.
Helical gears are similar to spur gears and of the same family of gears, however the teeth of a helical gear are angled to the gear face to better mesh with the driving worm gear insuring greater performance while preventing binding or lockup.
While addressing anti-siphon ability as with the other devices heretofore mentioned this particular device also addresses back flow prevention when the stopper is reseated by water pressure, but will not stop back flow if water pressure is lost during fill up. As previously discussed above this invention utilizes a start arm with a pawl to ratchet forward the cam to allow a predetermined volume of water by notches fixed in the cam. While this method appears to be able to work well a shortcoming to address is each toilet with a different tank capacity would need a special cam for that particular volume of water, additionally this ratchet cam system does not address the ability to adjust the volume of water metered so a 3.5 gallon valve will not service the 1.5 gallon tank of a newer toilet or vise versa. In other words one size does not fit all due to the arrangement of the fixed setting or position of notches in the cam and the ratcheting mechanism.
SUMMARY OF THE INVENTION
Accordingly, the reader will see that the instant invention is a toilet fill valve designed to operate in conjunction with or without its float assembly by providing a limited amount of water to any given toilet tank during flushing sufficient to allow a complete flush and performing a positive shut off of the water supply should the flushing operation fail for any reason. Should the float or flapper fail to operate properly and only after the maximum amount of water limited by volume has passed to the tank of a toilet, or water closet, the flo-control valve of the instant invention will close and prevent further entry of water into the tank for the purpose of eliminating running or wasting of water, preventing over flow and water damage. Additionally the fill valve is equipped with a back flow prevention check valve to stop any possible reverse flow in case of water pressure loss. The volume limiting shut-off action of the flo-control system, which can be used on any common toilet tank of sufficient dimension, comprises a flo-control valve positioned to turn on and shut off the flow of water from the feed line to the tank. The water flows from the feed line into the inlet through a channel in which the flo-control valve stopper is positioned, flow continues to a vaned water driven impeller assembly and thence to the inlet section of a float valve or a water delivery chamber and on to the outlet of whichever is used such that, during water flow the water driven impeller is caused to rotate within a channeled flow chamber. A worm gear, attached to the water driven impeller rotating therewith then drives a helical spur gear that is part of a vertical secondary gear assembly having a second worm gear on the upper end thereof. The worm gear of the intermediate gear assembly engages a horizontal helical spur gear of the same dimension which in turn rotates the final drive worm gear, which retracts the hold/release lever. The final drive worm gear, and the hold/release lever, control the positioning of the flo-control valve stopper in either a hold open or a released closed position.
When the toilet is flushed, the actuating lever depresses and dislodges the flo-control valve stopper to start the flow of water to fill the toilet tank. When the flo-control valve stopper is depressed the actuator lever causes the hold/release lever to disengage and retract from the final drive worm gear allowing the actuator lever to drop below the hold/release lever. When the flush lever is released the upward movement of a spring connected to the lower portion of the flo-control valve stopper causes the hold/release lever to engage the final drive worm gear while leaving the flo-control valve stopper open.
The water flows through the inlet, past the open flow-control valve stopper on to the impeller causing it to rotate. The rotating impeller then drives the gear assembly to cause the final drive worm gear to retract the hold/release lever releasing and allowing the actuator lever to be elevated by the closing of the flo-control actuator valve stopper, thereby effectively shutting off the flow of water. Noting that the shutting off the flow of water by the flo-control valve stopper is dependant on the failure of one or more of the flushing components of the toilet tank after allowing the full volume of water allowed or limited by the flo-control. An alternate means of controlling the actuator release is achieved by removing the hold release lever system and replacing it with a slotted disk system utilizing the same embodiment and majority of the components with some alterations which will be discussed further on.
Ideally the float assembly affixed to the uppermost portion of the valve body will be activated prior to the closing of the flo-control valve stopper. The flo-control valve will reset to its maximum allowance of water volume each time the flush lever is depressed. Any toilet tank that has a lesser volume capacity will cause the float valve to elevate and effectively shut off the flow of water. Should the float or flapper fail to close, the tank would call for more water than allowed and the flo control valve will shut off the flow of water when the limited volume of water has been reached effectively conserving water and reducing the volume of sewage waste caused by toilets that continuously run. In effect and operation the function of the instant invention is to shut off the water supply upon any malfunction of the toilet flushing system for any reason.
The reader will note that there are two interchangeable water delivery systems one being a float assembly and the other being a water delivery chamber. When using a float assembly the flo-control can be used universally in any tank irregardless to a lesser tank capacity. For instance a 1½ gallon tank will cause the float to shut the flow of water off at 1½ gallons and the flo-control will stop running. If there is a flapper leak or other malfunction the flo-control will still shut off at 3½ gallons limiting the maximum flow of water as its intended safety feature. The flo-control will also reset to its maximum allowance at every flush.
Said water delivery chamber system attaches to the flo-control the same way as the float assembly. However this system is simply a channeling device that directs the water downward towards the base of the tank for fill up from a delivery tube, with a replenish tube nipple at its upper most portion for removable connecting the replenish tube to restore the water level in the bowl during fill up.
OBJECTS AND ADVANTAGES
Accordingly, being designed to address the problems of toilets that have been discussed with the prior art, several objects and advantages of the present invention are:
(a) to provide a limited supply of water by volume to any given toilet tank per flush; (b) to provide a failsafe positive shutoff of the water feed line when the maximum limit of water by volume has been reached; (c) to prevent overflow and limit the extent of water damage from a plugged toilet; (d) to conserve water, and to prevent wasting of water; (e) to reduce municipal waste water treatment costs; (f) to reduce the production of sewage pollution into the environment; (g) to provide a positive means of anti-siphon and back flow prevention.
Further objects and advantages are to provide a cost effective easy to install toilet fill valve that will not interfere with servicing of other toilet tank parts. For instance with the present invention should the flapper of the flush valve not seat properly or worse yet rupture the water supply will be shut off and the toilet tank will be left empty and ready for easy no muss or fuss servicing. A new flapper can be installed or the flapper can be adjusted without taking too much time for cleanup, and once the repair is complete all that is necessary to return to normal flushing operation is to activate the flow of water by depressing the flush lever of the toilet tank and your back in business.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWING
The present invention will be better understood from the following detailed description as depicted in the drawings in which like reference numerals refer to like parts; closely related figures have the same number but different alphabetic suffixes.
FIG. 1 is a side view of a typical conventional toilet, with the tank partially cut away to reveal its interior, incorporating the automatic water limiting, supply shut off valve of the present invention;
FIG. 2 is a top plan view of the principal portion of the toilet tank of FIG. 1 with the lid removed, taken on line I—I of FIG. 1 ;
FIG. 3 is a cutaway front view of the inlet fitting, back flow chamber assembly and flo-control valve stopper.
FIG. 3A is a cutaway view side view of the flo-control valve assembly;
FIG. 3B is a front view of the drive impeller and the impeller drive flow chamber base plate, taken on line II—II and line III—III of FIG. 3A ;
FIG. 4 is a front view of the actuator lever and lever flush extension, taken on line II—II of FIG. 3A ;
FIG. 4A is a side view of the actuator lever;
FIG. 5 is a interior front view of the flo-control body rear wall, taken on line II—II and line III—III of FIG. 3A ;
FIG. 5A is a interior rear view of the flo-control cover, taken on line II—II and line III—III of FIG. 3A ;
FIG. 6 is a elevated view of the hold/release lever;
FIG. 7 is a cut away view of the float valve coupling;
FIG. 8 is a front cut away view of a water delivery chamber and replenish tube.
FIG. 9 is a cut away side view of a modified adjustable volume flo-control assembly using a slotted disk release system;
FIG. 9A is a rear view of the slotted disk and gear for the slotted disk release system;
FIG. 9B is a side view of the adjusting pegs for the slotted disk release system;
FIG. 9C is a front view of the replacement actuator for the alternate volume flo-control release system taken on line II—II of FIG. 3A , for the slotted disk release system;
FIG. 9D is a side view of the replacement actuator for the slotted disk release system;
DETAILED DESCRIPTION OF THE INVENTION
The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor for those so skilled to do so.
FIG. 1 is a side view of a conventional toilet, of the type universally found in most homes in the United States and North America, which is fitted with a water limiting flo-control valve 32 , in accordance with the present invention In the conventional home toilet, a float valve assembly 122 , comprising a float rod 9 , and a float 11 , FIGS. 1 and 2 , mounted at the upper end of a float valve assembly 122 , for closing the valve by means of linkage to the float 11 , with float rod 9 , when the tank is filled to a predetermined level. In the present invention a float valve assembly 122 , is affixed to the uppermost portion of the water limiting flo-control valve 32 , by means of a float coupling 124 .
The illustrated toilet comprises a toilet bowl 12 , and a pedestal 13 , with a tank 10 , mounted over the rear extension of toilet bowl and pedestal 13 . Water supply is introduced by means of a water feed line 34 , which is connected by known means of a standard sized fitting, commonly used with flush tanks, providing a sealable mount to the tank 10 , and a inlet fitting 36 , of the water limiting flo-control valve 32 . Water received in tank 10 which exceeds the tank's design capacity spills into an overflow tube 26 , wherefrom it is discharged to the bowl 12 . The main tank outlet 22 , is normally closed by a flapper 20 . When water from overflow tube 26 , and tank outlet 22 , is introduced into toilet bowl 12 , the level of water in bowl 12 , is raised until it exceeds the waste outlet of a flush trap 28 , causing the water to flow from bowl 12 , by siphoning action. Water, and waste products, continue to flow from bowl 12 , as long as sufficient water enters bowl 12 .
FIG. 2 is a top plan view of the principal portion of the toilet tank of FIG. 1 with the lid removed, illustrating the position of a flapper 20 , along line I—I of FIG. 1 and the position of the water limiting flo-control valve 32 , to the left most bottom portion of the tank 10 . A flush handle 14 , located in the upper left front area of the tank 10 , is depressed to activate the flushing operation of the toilet. When depressed the flush handle raises a flush rod 16 , opening a flapper 20 , by means of a flexible flapper flush linkage 18 , simultaneously said flush rod 16 , by means of a flexible flo-control flush linkage 24 , connected to a actuator lever flush extension 106 , activates the water limiting flo-control valve 32 , allowing water to flow to the tank 10 .
FIGS. 3–3B are illustrations of assembled components of the water limiting flo-control valve 32 , the Automatic Water Limiting, Supply Shut Off Safety Valve system according to the preferred embodiment of the present invention. The preferred embodiment is intended to limit the passing of up to 3.5 gallons of water by volume to the tank 10 , and to shut off the water supply. FIGS. 4–4A are illustrations of the actuator lever 104 , and actuator lever flush extension 106 . FIGS. 5–5A illustrate partial views of the interior of the flo-control body 66 , flo-control cover 72 , and the flo-control body seal 78 . FIG. 6 illustrates an elevated view of a hold/release lever 110 . FIG. 7 illustrates a sectional front view of the float valve coupling 124 . FIG. 8 illustrates a water delivery chamber 125 , and a replenish tube 30 .
The preferred embodiment of the present invention is molded in three sections of a plastic material that may be sealed when joined with o rings or other suitable gasket type threading seal or bonding material of the manufacturers choice. A back flow prevention chamber 42 , illustrated in FIG. 3 , demonstrates an inlet fitting 36 , comprised of a water inlet chamber 38 , fitted with a particle screen 40 , for trapping any foreign particles that may enter the water supply. Slightly above said inlet chamber 38 , molded in the embodiment of the inlet fitting is a back flow prevention chamber 42 . A back flow seat 44 is centered in said back flow chamber with a minimum ¼ inch diameter opening for water flow between the inlet chamber 38 , and the back flow prevention chamber 42 . Freely sitting on said back flow seat 44 , is a back flow check ball 46 , made of sufficient rubberized or metal material as to be non corrosive, non-buoyant and of sufficient diameter so as to block the opening for the water flow to prevent back-flow without becoming lodged. During water flow, the force of the water will lift the back flow check ball 46 , off the back flow seat 44 , allowing free flow of the water through the system. When water flow stops or at any time should the water supply lose its pressure the water will cease to flow causing the back flow check ball 46 , directed by the tapered wall of the back flow prevention chamber 42 , to reseat itself preventing reverse flow of water. At the center portion of back flow prevention chamber 42 , a mounting flange 48 , of the standard size to fit the receiving hole of the toilet tank 10 , fitted with a standard size flange seal 50 , of appropriate material between a mounting flange 48 , and the tank 10 , is affixed or mounted to said tank 10 , by means of the standard flange nut not shown for obvious reason.
Threaded into the upper most end of the inlet fitting 36 , and sealed by means of suitable plumber joint material or bonding material is a flo-control inlet coupling 52 . A flo-control valve stopper 58 , fitted with a o ring seal 60 , is attached to a open cross spring retainer pin 54 , of a flo-control inlet coupling 52 , by means of a flo-control valve spring 56 , preferably made of a non corrosive material such as stainless steel of sufficient diameter wire to create enough upward pressure to seat and hold said flo-control valve stopper 58 , in its closed position while still allowing the flo-control valve stopper 58 , to be unseated without excessive force.
The upper most portion of the flo-control inlet coupling 52 , is threaded and sealed by means of plumber joint material into a coupling receiver 53 . The flo-control valve stopper 58 , is positioned vertically within the center most portion of a flo-control chamber 62 , of preferred embodiment of the flo-control body 66 . FIG. 3A .
Section two preferably molded of a plastic material in two pieces, illustrated in FIG. 3A , FIG. 3 B, FIG. 5 , and FIG. 5 A, comprises a flo-control body 66 , and a flo-control cover 72 , that is sealed by placing a flo-control body seal 78 , between the flo-control cover 72 , and the flo-control body 66 , and placing a actuator o ring 108 , in a actuator receiver 77 , prior to aligning the actuator with a cover actuator hole 76 , then snapping the flo-control cover 72 , in place. Sealing of the housing is necessary to create driving water flow and to meet the plumbing requirements for “anti-siphoning”. The composition used for flo-control body 66 , would be a moldable plastic material of the manufacturers choice.
The flo-control cover 72 , FIG. 5 , is snapped into place by means of a set of flo-control cover guides 73 , mated to said guides by means of a matching set of cover guide receivers 74 , held in place by a body/cover locking ridge 7 . Said flo-control cover 72 , aids in directing the flow of water by means of a cover flow guide 75 , that aid in driving the rotation of a drive impeller 80 .
Mating of the flo-control valve stopper 58 , and a flo-control valve o ring 60 , to a flo-control valve seat 64 , is accomplished by means of threading the flo-control inlet coupling 52 , into the lower most portion of the flo-control chamber 62 , of the preferred embodiment of the flo-control body 66 , thereby extending the upper most portion of the flo-control valve stopper 58 , through the upper most portion of the flo-control chamber 62 , between the walls of a lower actuator guide 117 .
When unseated by means of a actuator lever 104 , the flo-control valve stopper 58 , allows water to flow through said valve into the upper most portion of the flo-control valve chamber 62 , and on into a impeller drive flow chamber 68 , FIGS. 3A and 3B directed by means of a lower body flow guide 63 , FIG. 5 , creating an opening between said chambers. Preferably molded of a plastic material the components of the impeller drive flow chamber 68 , are comprised of a impeller drive flow chamber base plate 69 , a flo-control cover 72 seals the flow chamber when snapped into place as previously described. The impeller drive flow chamber base plate 69 , directs the flow of water by means of a split flow guide 70 , located at the lower most portion of base plate 69 , which forces the flow of water to turn a drive impeller 80 . The split flow guide 70 , FIG. 3 B, is comprised of two parallel walls of sufficient and equal extension at a 90 degree angle outwardly from the face of the impeller drive flow chamber base plate 69 , so as to allow sufficient space to form a chamber when covered with said flo-control cover 72 , to allow free wheeling of a drive impeller 80 . A spacing peg 71 , of equal extension molded to the uppermost end of base plate 69 , opposite the split flow guide 70 , assures equal distance between said impeller drive flow chamber base plate 69 , and the flo-control cover 72 , at all points.
The impeller drive flow chamber 68 , houses the drive impeller 80 , FIG. 3B , molded as a one piece unit with a primary drive worm gear 82 , to the rear most portion of its center. The impeller primary drive worm gear 82 , is centered and mounted through said impeller drive flow chamber base plate 69 , by means of a impeller drive shaft 84 , composed of a non corrosive metal, mounted horizontally from front to rear with a primary drive shaft bushing 83 , to the rear of the primary drive worm gear 82 , between a drive shaft receiver 85 , recessed in the inside of the flo-control cover 72 , and a body drive shaft receiver 94 , recessed in the inside of the flo-control body 66 , locked in a certain position on said impeller drive shaft 84 , by means of a retainer ring 86 , as shown in FIGS. 3A and 3B . Said impeller 80 , solidly connected to primary drive worm gear 84 , is caused to rotate by means of the force of water flow through the impeller drive flow chamber 68 , against a impeller fin 81 , in the flow path. The impeller fins 81 , are evenly space to insure a fin will enter the flow path as a fin leaves the flow path maintaining a constant rotation of the drive impeller 80 , during water flow with a minimum of four fins in the flow path at all times FIG. 3B .
The primary drive worm gear 82 , engages a secondary drive helical gear 88 , solidly molded as a one piece unit with a secondary drive worm gear 90 , of a suitable material. Said secondary helical gear meshes with said primary drive worm gear 82 , at its 90 degree right center horizontally. Said secondary worm gear 90 , is vertically positioned by means of a secondary drive gear bracket 92 , Two secondary drive gear brackets 92 , are mounted horizontally parallel to each other, one above the other, spaced a sufficient distance apart so as to accommodate the length and fixing the position of said secondary drive helical gear 88 , and secondary drive worm gear 90 . Said secondary drive gear brackets 92 , are mounted from front to back by means of a secondary drive bracket mount 96 , molded into the rear most side of the impeller drive flow chamber base plate 69 , and the front most inside of the rear wall of the flo-control body 66 , illustrated in FIG. 3A .
The secondary drive worm gear 90 , then engages a final drive helical gear 98 , solidly molded as a one piece unit with a final drive double thread worm gear 100 , of a suitable material. Said final drive helical gear 98 , meshes with said secondary worm gear 90 , at its center 90 degrees to its left and centered above said primary worm gear 82 . Final drive double thread worm gear 100 , is horizontally positioned from front to back by means of two final drive gear shaft studs 102 , one being molded to the rear side of the impeller drive flow chamber base plate 69 , 180 degrees horizontally to the other being molded to the front inside of the rear wall of the flo-control body 66 , spaced a sufficient distance apart so as to accommodate the length and fix the position of said final drive gears.
When flush handle 14 , FIG. 2 , is depressed the flo-control flush linkage 24 , elevates the actuator lever flush extension 106 , FIG. 3B and FIG. 4 , Connected by means of a lever connector 107 , causing a actuator lever 104 , to move in a downward motion between a lower actuator guide 117 , and a upper actuator guide 118 , FIG. 5 , by means of a beveled surface 105 , pushing a hold/release lever 110 rearward. The hold/release lever 110 , is connected to and positioned by means of two retainer pins 109 FIG. 6 , mated to two retainer slots 116 , in a hold/release lever receiver 115 , molded into the preferred embodiment of the flo-control body, FIGS. 3A and 5 , and a hold/release lever spring 112 , composed of a non corrosive material of sufficient diameter wire to provide a slight forward tension FIG. 3A , held in position by two spring pins 113 . One spring pin 113 , being molded to the rear most center within the hold/release lever receiver 115 , and the other spring pin 113 , molded to the centered rear most end of the hold/release lever 110 . The passing of the beveled surface 105 , against a mated beveled surface 111 , of the actuator lever 104 , forces the hold/release lever 110 , to move rearward into the hold/release lever receiver 115 . After the actuator lever 104 , pushes past the hold/release lever 110 in a downward motion, said lever 110 , by means of tension supplied by the hold/release lever spring 112 , moves forward resting on top of actuator lever 104 holding actuator lever 104 in its down most position. Simultaneously actuator lever 104 , unseats and holds open the flo-control valve stopper 58 , in the same downward motion. When the flush handle 14 is released it returns to its normal resting position allowing the actuator lever 104 , by means of tension of the flo-control valve spring 56 , to be pushed upward causing the hold/release lever 110 , to gearably engage a gear rack 114 , molded to the upper most surface of said hold/release lever 110 FIG. 6 , to the final drive double thread worm gear 100 , thereby holding the flo-control valve stopper 58 , open.
The drive impeller 80 , is caused to rotate by means of the force of water flowing through the impeller drive flow chamber 68 . The rotational energy delivered to the final drive double thread worm gear 100 , being gearably linked to said drive impeller 80 , as heretofore described causes the hold/release lever 110 , to retract into the hold/release lever receiver 115 , by means of said gear rack 114 , thereby releasing the actuator lever 104 . Upon release, the actuator lever 104 , is repositioned above said hold/release lever 110 , by means of elevation due to the upward movement of the flo-control valve stopper 58 , being reseated by means of the force of the flo-control valve spring 56 , and the water pressure terminating the flow of water completing the flush cycle. During the time the flo-control valve stopper 58 , is held open while the water passes through the impeller drive flow chamber 68 , to the outlet by means of a upper body flow guide 65 , molded within the flo-control body 66 , at its upper most interior forcing the water out the water outlet 120 , FIG. 5 .
The reader will note that there are two ways in which the water can be delivered to the tank 10 . The first and most obvious means to deliver water to the tank 10 , a float assembly 122 , illustrated in FIGS. 1 and 2 . The second means to deliver water to the tank 10 , is a water delivery chamber 125 , FIG. 8 , which will be discussed further on.
Section three is a float assembly 122 , FIG. 1 and FIG. 2 , attached to the present invention by means of a water outlet 120 , at the upper most end of the flo-control valve 32 , FIGS. 1 and 2 , on line II—II of FIG. 3A , molded at the upper most portion of the preferred embodiment of the flo-control body 66 , by means of mating thread of the lower most end of a float coupling 124 FIG. 7 , to the thread of said water outlet 120 , sealed with an o ring or other suitable gasket type or thread sealing material. Threading or bonding with a suitable bonding agent of the coupling 124 , to the float valve inlet while eliminating a portion the older type extension tube from the float valve to the tank mount. Where the float valve is now connected to the flo-control valve 32 , the siphon tube becomes a replenish tube 30 , FIGS. 1 , 2 and 8 , which is removeably attached the a siphon tube nipple of the float assembly 122 , for the purpose of replenishing the proper water level to the bowl 12 .
The second means to deliver water to the tank 10 , is a water delivery chamber 125 , FIG. 8 . The preferred embodiment of the water delivery chamber 125 , FIG. 8 , is a one piece mold of appropriate plastic material comprised of a chamber inlet 126 , threaded to mate the flo-control water outlet 120 . However, this system is simply a channeling device that directs the water downward towards the base of the tank for fill up by means of an water delivery chamber 127 , and an chamber outlet 128 , with an eliminator replenish tube nipple 130 , at its upper most portion for removeably connecting a replenish tube 30 . Said replenish tube 30 , is attached to the over flow tube 26 , by means of a replenish tube clip 132 , to restore the water level in the bowl during fill up. With this optional water delivery chamber 125 , attached to the flo-control valve 32 , the flo-control will run to its full limit of 3½ gallons and shut off the water feed every time. In order to fill different capacity tanks the hold/release levers beveled surface 111 , would have to be shortened or lengthened. That is to say for example if the hold/release lever 110 , required to be retracted ⅜ of an inch for release to shut off the flo-control at 4½ gallons then it would be required to be retracted ⅛ of an inch to shut off at 1½ gallons. The length would have to be shortened ¼ inch for that adjustment. This would require at least three different size hold/release levers and each flo-control would be marked appropriately on its packaging as to its limit.
DETAILED DESCRIPTION OF THE MODIFIED VERSION OF THE INVENTION
The following description of a modified version of the invention for the purpose of easily adjusting the gallon per flush volume of the flo-control valve 32 , is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor for those so skilled to do so. To coincide with this modified version of the invention the reader is referred to illustrations of FIGS. 1 , 2 , 3 , 3 B, 5 , 5 A, 7 , 8 , and FIGS. 9–9D . The reader will also note that being that this is a modified the numbers of the parts in the forgoing description that are not modified will remain the same, modified parts will have either an A extension or a number of their own.
FIG. 1 is a side view of a conventional toilet, of the type universally found in most homes in the United States and North America, which is fitted with a water limiting flo-control valve 32 , in accordance with the present invention. In the conventional home toilet, a float valve assembly 122 , comprising a float rod 9 , and a float 11 , FIGS. 1 and 2 , mounted at the upper end of a float valve assembly 122 , for closing the valve by means of linkage to the float 11 , to the float valve with float rod 9 , when the tank is filled to a predetermined level. In the present invention the float valve assembly 122 , is affixed to the uppermost portion of the water limiting flo-control valve 32 , by means of a float coupling 124 .
The illustrated toilet comprises a toilet bowl 12 , and a pedestal 13 , with a tank 10 , mounted over the rear extension of toilet bowl and pedestal 13 . Water supply is introduced by means of a water feed line 34 , which is connected by known means of a standard sized fitting, commonly used with flush tanks, providing a sealable mount to the tank 10 , and a inlet fitting 36 , of the water limiting flo-control valve 32 . Water received in tank 10 which exceeds the tank's design capacity spills into an overflow tube 26 , wherefrom it is discharged to the bowl 12 . The main tank outlet 22 , is normally closed by a flapper 20 . When water from overflow tube 26 , and tank outlet 22 , is introduced into toilet bowl 12 , the level of water in bowl 12 , is raised until it exceeds the waste outlet of a flush trap 28 , causing the water to flow from bowl 12 , by siphoning action. Water, and waste products, continue to flow from bowl 12 , as long as sufficient water enters bowl 12 .
FIG. 2 is a top plan view of the principal portion of the toilet tank of FIG. 1 with the lid removed, illustrating the position of a flapper 20 , along line I—I of FIG. 1 and the position of the water limiting flo-control valve 32 to the left most bottom portion of the tank 10 . A flush handle 14 , located in the upper left front area of the tank 10 , is depressed to activate the flushing operation of the toilet. When depressed the flush handle raises a flush rod 16 , opening a flapper 20 , by means of a flapper flush linkage 18 , simultaneously said flush rod 16 , by means of a flo-control flush linkage 24 , connected to a actuator lever flush extension 106 illustrated in FIG. 9C , activates the water limiting flo-control valve 32 , allowing water to flow to the tank 10 .
FIGS. 3 , 3 B and FIG. 9 are illustrations of assembled components of the water limiting flo-control valve 32 , the Automatic Water Limiting, Supply Shut Off Safety Valve system according to the preferred embodiment of the present invention. The preferred embodiment is intended to limit the passing of up to 3.5 gallons of water by volume to the tank 10 , and to shut off the water supply. FIGS. 9–9B illustrate a modified water volume adjustable releasing mechanism for releasing a flo-control valve stopper 58 , by means of a slotted disk 140 , and a volume adjusting peg 150 . FIGS. 9C and 9D illustrate a actuator lever 154 , for use with the modified water volume adjustable mechanism.
The preferred embodiment of the present modified invention is molded in three sections of a plastic material that may be sealed when joined with o rings or other suitable gasket type threading seal or bonding material of the manufacturers choice. Section one illustrated in FIG. 3 , being the assembled parts of a inlet fitting 36 , comprised of a water inlet chamber 38 , fitted with a particle screen 40 , for trapping any foreign particles that may enter the water supply. Slightly above said inlet chamber 38 , molded in the embodiment of the inlet fitting is a back flow prevention chamber 42 . A back flow seat 44 is centered in said back flow chamber with a minimum ¼ inch diameter opening for water flow between the inlet chamber 38 , and the back flow prevention chamber 42 . Freely sitting on said back flow seat 44 , is a back flow check ball 46 , made of sufficient rubberized or metal material as to be non corrosive, non-buoyant and of sufficient diameter so as to block the opening for the water flow to prevent back-flow without becoming lodged. During water flow, the force of the water will lift the back flow check ball 46 , off the back flow seat 44 , allowing free flow of the water through the system. When water flow stops or at any time should the water supply lose its pressure the water will cease to flow causing the back flow check ball 46 , directed by the tapered wall of the back flow prevention chamber 42 , to reseat itself preventing reverse flow of water. At the center portion of back flow prevention chamber 42 , a mounting flange 48 , of the standard size to fit the receiving hole of the toilet tank 10 , fitted with a standard size flange seal 50 , of appropriate material between a mounting flange 48 , and the tank 10 , is affixed or mounted to said tank 10 , by means of the standard flange nut not shown for obvious reason.
Threaded into the upper most end of the inlet fitting 36 , and sealed by means of suitable plumber joint material or bonding material is a flo-control inlet coupling 52 . A flo-control valve stopper 58 , fitted with a o ring seal 60 , is attached to a open cross spring retainer pin 54 , of a flo-control inlet coupling 52 , by means of a flo-control valve spring 56 , preferably made of a non corrosive material such as stainless steel of sufficient diameter wire to create enough upward pressure to seat and hold said flo-control valve stopper 58 , in its closed position while still allowing the flo-control valve stopper 58 , to be unseated without excessive force.
The upper most portion of the flo-control inlet coupling 52 , is threaded and sealed by means of plumber joint material into a coupling receiver 53 . The flo-control valve stopper 58 , is positioned vertically within the center most portion of a flo-control chamber 62 , of preferred embodiment of the flo-control body 66 . FIG. 3A .
Section two preferably molded of a plastic material in two pieces, illustrated in FIG. 9 , FIG. 3 B, FIG. 5 , and FIG. 5A , comprises a flo-control body 66 , and a flo-control cover 72 , that is sealed by placing a flo-control body seal 78 , between the flo-control cover 72 , and the flo-control body 66 , and placing a actuator o ring 108 , in a actuator receiver 77 , prior to aligning the actuator with a cover actuator hole 76 , then snapping the flo-control cover 72 , in place. Sealing of the housing is necessary to create driving water flow and to meet the plumbing requirements for “anti-siphoning”. The composition used for flo-control body 66 , would be of a moldable plastic material the manufacturers choice. The flo-control cover 72 , FIG. 5 , is snapped into place by means of a set of flo-control cover guides 73 , mated to said guides by means of a matching set of cover guide receivers 74 , held in place by a body/cover locking ridge 7 . Said flo-control cover 72 , aids in directing the flow of water by means of a cover flow guide 75 , that aid in driving the rotation of a drive impeller 80 .
Mating of the flo-control valve stopper 58 , and a flo-control valve o ring 60 , to a flo-control valve seat 64 , is accomplished by means of threading the flo-control inlet coupling 52 , into the lower most portion of the flo-control chamber 62 , of the preferred embodiment of the flo-control body 66 , thereby extending the upper most portion of the flo-control valve stopper 58 , through the upper most portion of the flo-control chamber 62 , between the walls of a lower actuator guide 117 .
When unseated by means of a actuator lever 154 , the flo-control valve stopper 58 , allows water to flow past said flo-control valve stopper 58 into the upper most portion of the flo-control valve chamber 62 , and on into a impeller drive flow chamber 68 , FIGS. 3A and 3B directed by means of a lower body flow guide 63 , FIG. 5 , creating an opening between said chambers. Preferably molded of a plastic material the components of the impeller drive flow chamber 68 , are comprised of a impeller drive flow chamber base plate 69 , a flo-control cover 72 seals the flow chamber when snapped into place as previously described. The impeller drive flow chamber base plate 69 , directs the flow of water by means of a split flow guide 70 , located at the lower most portion of base plate 69 , which forces the flow of water to turn a drive impeller 80 . The split flow guide 70 , FIG. 3 B, is comprised of two parallel walls of sufficient and equal extension at a 90 degree angle outwardly from the face of the impeller drive flow chamber base plate 69 , so as to allow sufficient space to form a chamber when covered with said flo-control cover 72 , to allow free wheeling of a drive impeller 80 . A spacing peg 71 , of equal extension molded to the uppermost end of base plate 69 , opposite the split flow guide 70 , assures equal distance between said impeller drive flow chamber base plate 69 , and the flo-control cover 72 , at all points.
The impeller drive flow chamber 68 , houses the drive impeller 80 , FIG. 3B , molded as a one piece unit with a primary drive worm gear 82 , to the rear most portion of its center. The primary drive worm gear 82 , is centered and mounted through said impeller drive flow chamber base plate 69 , by means of a impeller drive shaft 84 , composed of a non corrosive metal, mounted horizontally from front to rear with a slotted disk 140 , solidly molded to a spur gear 142 , mounted to the rear of the primary drive worm gear 82 , between a drive shaft receiver 85 , recessed in the inside of the flo-control cover 72 , and a body drive shaft receiver 94 , recessed in the inside of the flo-control body 66 , locked in a certain position on said impeller drive shaft 84 , by means of a retainer ring 86 , as shown in FIG. 3B and FIG. 9 . Said impeller 80 , solidly connected to primary drive worm gear 84 , is caused to rotate by means of the force of water flow through the impeller drive flow chamber 68 , against a impeller fin 81 , in the flow path. The impeller fins 81 , are evenly space to insure a fin will enter the flow path as a fin leaves the flow path maintaining a constant rotation of the drive impeller 80 , during water flow with a minimum of four fins in the flow path at all times FIG. 3B .
A primary drive worm gear 82 , engages a secondary drive helical gear 88 , solidly molded as a one piece unit with a secondary drive worm gear 90 , of a suitable material. Said secondary helical gear meshes with said primary drive worm gear 82 , at its 90 degree right center horizontally. Said secondary worm gear 90 , is vertically positioned by means of a secondary drive gear bracket 92 . Two secondary drive gear brackets 92 , mounted horizontally parallel to each other, one above the other, spaced a sufficient distance apart so as to accommodate the length and fixing the position of said secondary drive helical gear 88 , and secondary drive worm gear 90 . Said secondary drive gear brackets 92 , are mounted from front to back by means of a secondary drive bracket mount 96 , molded into the rear most side of the impeller drive flow chamber base plate 69 , and the front most inside of the rear wall of the flo-control body 66 , illustrated in FIG. 3A .
A secondary drive worm gear 90 , then engages a final drive helical gear 98 , solidly molded as a one piece unit with a intermediate drive spur gear 134 , of a suitable material. Said final drive helical gear 98 , meshes with said secondary worm gear 90 , at its center 90 degrees to its left and centered above said primary worm gear 82 . Final drive helical gear 98 , and intermediate spur gear 134 , are vertically positioned from front to rear by means of two final drive gear shaft studs 102 , one being molded to the rear side of the impeller drive flow chamber base plate 69 , 180 degrees horizontally to the other being molded to the front inside of the rear wall of the flo-control body 66 , spaced a sufficient distance apart so as to accommodate the length and fix the position of final drive helical gear 98 , and intermediate spur gear 134 .
Intermediate spur gear 134 , drives a tapered face spur gear 136 , held in the engaged position by means of a spring 139 , mounted to the embodiment of the flo-control body 66 , by means of a jack shaft 138 . Solidly molded on one face of the tapered face spur gear 136 , is a tapered rise 137 , FIG. 9 . When engaged tapered face spur gear 136 , drives a spur gear 142 , solidly connected to a slotted disk 140 , mounted on a impeller drive shaft 84 , to the rear of the primary drive worm gear 82 . The slotted disk 140 , FIG. 9A , comprises a actuator release slot 146 , FIG. 9A , the means which allows opening and closing of the flo-control valve stopper 58 . The adjustment of gallons allowed from 1.5 gallons to 3.5 gallons is accomplished by means of a volume adjusting slot 148 , and a volume adjusting peg 150 , FIG. 9B . There are three volume adjusting pegs of a different diameter to fit the volume adjusting slot 148 , allowing the slotted disk 140 , to turn when the toilet is flushed to the limit set by the peg 150 , inserted into a adjusting peg receiver 152 , illustrated in FIGS. 9 , and 9 A, sealed with a adjusting peg o ring 153 . The slotted disk 140 , is held in the valve closed position by means of a actuator foot 156 , of the actuator 154 , illustrated in FIGS. 9C and 9D , mated to the actuator release slot 146 , FIG. 9A . The actuator lever 154 , of the modified valve control mechanism is comprised of a actuator foot 156 , a tapered spur gear push 158 , and a start spring receiver hole 145 . A start spring receiver hole 145 , is also located in the slotted disk 140 . When the flush handle 14 , of the toilet is depressed the slotted disk 140 , is released by the actuator foot 156 and the disengaging of the tapered face spur gear 136 , by means of pushing rearward on said tapered rise 137 , from said actuator gear push 158 means, and is rotated to the limit of the selected volume adjusting peg 150 , by means of a start spring 144 , inserted into the slotted disk 140 , and the actuator lever 154 , by means of the start spring receiver hole 145 , simultaneously dislodging and opening the actuator valve 58 . When the flush handle 14 , is released the jack shaft spur gear re-engages. The actuator valve is held open by the slotted disk until the selected volume of water rotates the actuator release slot 146 , over the actuator foot 156 , by means of the gearably linked drive impeller thereby allowing the flo-control valve stopper 58 , to close.
Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiments which can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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A geared mechanical device designed to limit a finite amount of water per flush to a tank reservoir of the common household toilet, providing positive shutoff of flow and anti-siphon back flow prevention. The toilet is flushed, the actuator lever opens the flo-control valve stopper by means of linkage to the flush lever. The water enters the back flow chamber into the primary valve chamber thence to the flow control chamber, and on to the float valve into the toilet tank for fill up. Force of the water rotates the drive impeller gearably linked to the hold release mechanism. On release the flo-control valve stopper closes. The back flow prevention chamber allows the water to pass in the direction of flow and reseats itself when the flow has stopped or if water pressure is lost at any time eliminating a need for a anti-siphon tube. A replenish tube restores water level to the bowl. A water delivery chamber may be affixed to the flo-control in place of the float valve. For the purpose of adjusting the volume of water per flush a modified slotted disk hold release mechanism is used in the flo-control, gearably connected to the drive impeller.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a circulating valve for use in a well. Circulating valves are used to permit flow between two well conduits.
2. The Prior Art
In the completion or production of a well, a circulating valve is often installed to permit a high volume rate of flow between two of the well conduits. For example, it may be desired to kill a producing well to perform anyone of several operations. A circulating valve controlling flow between the tubing string bore and the annulus around the tubing string would be opened. Fluid would then be circulated through the circulating valve to kill the well.
Generally circulating valves have been activated by the use of wireline tools extending from the surface down into the well. For a deep well, use of wireline tools is expensive, poses a hazard of possible loss of tools in the well, requires time to run the tools into the well, and requires manipulation from the surface to affect opening of the valve.
Some circulating valves are pressure operated. U.S. Pat. No. 3,282,348 to Artigue discloses a pressure operated circulating valve which permits uni-directional flow through the valve and which moves to a closed position preventing any flow through the valve upon the application of a predetermined pressure differential across the valve. U.S. Pat. No. 3,807,428 to Watkins, et al discloses a circulating valve which is opened upon the application of a predetermined first absolute pressure and which is closed upon the application of a predetermined second higher absolute pressure.
Neither of circulating valves disclosed in the above patents permit any condition of flow through the valve once the valve is opened. The rate of flow through the circulating valves disclosed in the above patents is limited because only one flow path through the valve exists. In addition, the circulating valve disclosed in Watkins, et al would be uncontrollable in the event tubing pressure could not be controlled from the surface.
This invention is an improvement over the circulating valve disclosed in a copending application of William A. Dudley entitled "CIRCULATING VALVE" Ser. No. 661,249 filed Feb. 25, 1976 and also assigned to the assignee of this application.
OBJECTS OF THE INVENTION
An object of this invention is to provide a circulating valve for use in a well which upon opening retains an upper valve plug in a position permitting any condition of flow through the valve.
Another object of this invention is to provide a circulating valve for use in a well wherein an upper valve plug is retained in a position out of the flow path after the valve is opened.
Another object of this invention is to increase the rate of flow through a circulating valve by having two flow paths through the valve.
Another object of this invention is to provide a circulating valve with an increased flow rate having two flow paths wherein an upper valve plug is retained in a position permitting any condition of flow through the valve once the valve is opened.
Another object of this invention is to provide a circulating valve for use in a well wherein a circumferential seal around an upper valve plug body performs the dual functions of sealing between the plug body and a seal bore to prevent flow through the valve and of retaining the plug body in a pocket to permit flow through the valve.
Another object of this invention is to provide a circulating valve for use in a well with an increased flow rate wherein an upper valve plug is retained out of the flow path through the valve and a lower valve plug is caught in a pocket out of the flow path once the valve is opened.
These and other objects, and features of advantage of this invention, will be apparent, from the drawings, detailed description, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like numerals indicate like parts and wherein two embodiments of this invention are shown:
FIG. 1 schematically illustrates, in partial cross section, a circulating valve positioned in a well;
FIG. 2 is a quarter-sectional view of a first embodiment of a circulating valve with the valve closed;
FIG. 3 is a quarter-sectional view of the circulating valve of FIG. 2 with the valve open;
FIG. 4 is in part a quarter-sectional view and in part a view along the lines 5--5 of FIG. 6 and 7 of a second embodiment of a circulating valve with the valve closed;
FIG. 5 is a fragmentary view on an enlarged scale of the circulating valve of FIG. 4 with the valve open;
FIG. 6 is a cross-sectional view taken along line 6--6 in FIG. 5; and
FIG. 7 is a cross-sectional view taken along line 7--7 in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In a well, circulating valves provide a means for obtaining a high volume rate of flow between well conduits. The circulating valve of this invention is normally closed but opens upon a predetermined pressure differential across the valve and then remains open to any condition of flow through the valve. An increased rate of flow through the circulating valve of this invention is possible because the flow passage through the valve provides two flow paths.
In FIG. 1 a portion of a well for the production of fluids is shown. Into the well extend one or more casing string 10 to line the well wall. Through the casing string 10 extends a production tubing string 12 through which well fluids may be produced. To control flow between the annulus 14 around the tubing string 12 and the bore 16 of the tubing string 12, a circulating valve, generally indicated at 18, is positioned in the well.
The circulating valve 18 of this invention is adapted to be positioned within the side pocket receptacle 20 of a side pocket mandrel 22 within the production string 12, although other arrangements could be made for positioning the circulating valve 18 in the well. The side pocket mandrel may be conventional and includes a first port 24 communicating between the annulus 14 and the side pocket receptacle 20 and a second port 26 communicating between the bore 16 and the side pocket receptacle 20.
The circulating valve may be held in place within the side pocket receptacle 20 by a latch mechanism 28 capable of maintaining the circulating valve 18 within the side pocket receptacle 20 under an appreciable pressure differential.
A first embodiment of the circulating valve 30 is shown in greater detail in FIGS. 2 and 3.
The circulating valve, generally indicated at 30, includes a valve housing means 32, flow passage means through valve housing means 32, two valve plug means 36a and 36b initially closing the flow passage means and frangible draw bar means 38 to releasably maintain both valve plug means 36a and 36b in their initial position.
Valve housing means, generally indicated at 32, is adapted to be received within the side pocket receptacle 20 of a side pocket mandrel 22. Valve housing means 32 includes interconnected housing sections 32a, 32b, 32c, and 32d.
Surrounding valve housing means 32 are two spaced seal means 40 and 42 which are adapted to seal with the side pocket receptacle 20 of side pocket mandrel 22. The spaced seal means 40 and 42 define a seal area 44 and upper 46 and lower 48 end sections of valve housing means 32 to permit controlled flow of fluid through the circulating valve 30 when it is installed within the side pocket receptacle 20.
Flow passage means extends through valve housing means 32 to provide fluid communication between one of the defined seal area 44 and end sections 46 and 48, and the other two of said seal area 44 and end sections 46 and 48. In the illustrated circulating valve 30 fluid flow between the annulus 14 and the bore 16 is provided by a flow passage means including first circulating port means, generally indicated at 50 in valve housing means 32 between spaced seal means 40 and 42 in communication with first port 24 in side pocket mandrel 22 and also including upper 52a and lower 52b passage means extending through valve housing means 32 communicating between first circulating port means 50 and the upper 46 and lower 48 end section and of valve housing means 32 respectively. Flow passage means provides two flow paths through the circulating valve 30, each flow path providing fluid communication between the annulus 14 and the bore 16. A primary upper flow path extends from a first circulating port means 50a through upper passage means 52a and out a second circulating port means 54 in the upper end section 46 of valve housing means 32. The flow path from the annulus 14 to the bore 16 for this upper path then extends around the upper end section 46 of the circulating valve 30 and enters the bore 16 at the mouth of the side pocket receptacle 20 or at opening between seal means 40 and latch mechanism 28. A primary lower flow path extends from a first circulating port means 50b through a lower passage 52b and out third circulating port means 56 in the lower end section 48 of the valve housing means 32. The third circulating port means 56 is in communication with the second port 26 in the side pocket mandrel 22.
Both the upper and lower passage means 52a and 52b include a reduced diameter, seal bore portion 58a and 58b respectively in which the upper and lower valve plug means 36a and 36b, respectively are initially maintained, and an enlarged diameter portion 60a and 60b to reduce resistance to movement of each valve plug means 36a and 36b to an out-of-the-way position.
An upper and lower valve plug means 36a and 36b, respectively, control fluid flow through the flow passage means of the circulating valve 30. In the illustrated circulating valve 30, the valve plug means 36a and 36b are initially positioned in their respective seal bore portions 58a and 58b blocking flow through the upper and lower passage means 52a and 52b between first circulating port means 50 and the upper and lower end sections 46 and 48 of the circulating valve 30. Both valve plug means 36a and 36b include valve plug body means 62a and 62b, respectively, and circumferential seal means 64a and 64b on the respective valve plug body means 62a and 62b. Both seal means 64a and 64b are adapted to seal between valve plug of body means 62a and 62b and the wall of passage means 52 in the seal bore portions 58a and 58b when valve plug means 36a and 36b are in their initial position.
The circulating valve 30 is designed to be initially closed and to be opened upon a predetermined pressure differential across both valve plug means 36a and 36b. Frangible drawbar means 38 releasably maintains valve plug means 36a and 36b in their initial position closing flow passage means. Upon a predetermined pressure differential across valve plug means 36a and 36b, which in the illustrated circulating valve 30 is applied from the annulus 14 to the bore 16, frangible drawbar means 38 breaks permitting both valve plug means 36a and 36b to move to a position opening flow passage means. The size of frangible drawbar means 38 may be varied from one circulating valve assembly 30 to another to provide that the various circulating valve assemblies open at a different desired pressure differential within a range of pressure differentials. For example, different size frangible drawbar means 38 may be designed to break in 500 p.s.i. increments within a range of 1,500 p.s.i. to 3,000 p.s.i. differential pressure.
Once frangible drawbar means 38 breaks both valve plug means 36a and 36b move to a position permitting any condition of fluid flow between the tubing bore 16 and the annulus 14 and consequently through flow passage means.
Lower pocket means 66 is formed within valve housing means 32 to receive lower valve plug means 36b after frangible drawbar means 38 breaks. The illustrated lower pocket means 66 is below passage means 52b. Lower valve plug means 36b may thus be blown into lower pocket means 66 when frangible drawbar means 38 breaks due to the force of the pressure differential across the lower valve plug means 36b. Lower valve plug means will thereafter be maintained in lower pocket means 66 in an out-of-the-way position, out of flow passage means due to the force of gravity. There it will permit any desired condition of flow through passage means.
So that when lower valve plug means 36b is blown into lower pocket means 66, its movement is not retarded by fluid that may be within lower pocket means 66, bleed port means 68 is provided in valve housing means 32 communicating between lower pocket means 66 and the exterior of valve housing means 32.
Upper pocket means 70 is also formed within valve housing means 32 to receive upper valve plug means 36a after frangible drawbar means 38 breaks. Retainer means, generally indicated at 72, prevent upper valve plug means 36a from falling back down into a position blocking flow through upper passage means 52a once it has entered upper pocket means 70.
The illustrated upper pocket means 70 is above the flow passage means and opens into passage means 52a. Upper valve plug means 36a may thus be blown into upper pocket means 70 when frangible drawbar means 38 breaks due to the force of the pressure differential across upper valve plug means 36a.
Retainer means, generally indicated at 72, permits upper valve plug means 36a to enter upper pocket means 70 but prevents it from falling back down into passage means 52a. One preferred and illustrated retainer means 72 comprises an annular recess 74 in which is disposed an expandable and contractible retainer ring means 76. Recess means 74 is at the lower end of upper pocket means 70. Retainer ring means 76 has a downward facing annular chamfered surface 78 to permit upper valve plug means 36a to move upwardly past said retainer ring means into the upper pocket means 70 by expanding retainer ring means 76 outwardly into the annulus recess 74. Once upper valve plug means 36a has entered upper pocket means 70, retainer ring means 76 contracts and has an upward facing stop shoulder 80 to prevent upper valve plug means 36a from dropping out of the upper pocket means 70 (see FIG. 3).
With upper valve plug means 36a retained in upper pocket means 70 by retainer means 72 it will thereafter be in an out-of-the-way position out of the flow passage means and will thereafter permit any desired condition of flow through the flow passage means.
So that when upper valve plug means 36a is blown into upper pocket means 70 its movement is not retarded by fluid that may be within upper pocket means 70, bleed port means 82 is provided in valve housing means 32 communicating between upper pocket means 70 and the exterior of valve housing means 32.
The illustrated construction of circulating valve 30 simplifies its assembly and the replacement of parts after use.
To assemble the circulating valve 30, circumferential seal means 64 are positioned around each of the valve plug body means 62. One of the valve plug body means 62 is connected to frangible drawbar means 38 as by a threaded connection. Frangible drawbar means 38 with the attached valve plug body means 62 is then inserted within the valve housing section 32c. Then the other valve plug body means 62 is also connected to frangible drawbar means 38, as by another threaded connection. The connections are made up until a shoulder 83 of the upper valve plug means 36a engages a seat 84 and a shoulder 85 of the lower valve plug means 36b also engages a shoulder 86. Care should be taken not to prestress frangible drawbar means 38 as this would cause it to break at an undesired, lower pressure differential. Both valve plug means 36a and 36b are now releasably maintained within their seal bore portions 58a and 58b and will seal off both upper and lower passage means 52a and 52b. Housing sections 30a, 30b and 30d may now be assembled and connected to housing section 30c.
Once the circulating valve 30 has been used, frangible drawbar means 38 is replaced. If flow cutting has worn either seal bore portion 58a and 58b, valve housing section 30c is also replaced so that an effective seal may be obtained between valve plug body means 62 and the wall of the respective seal bore portion 58 when a valve plug means 36 is in its initial position.
In operation, the circulating valve 30 of this invention is used to control flow in a well. Extending through the well would be a casing string 10 and a tubing string 12 defining an annulus 14 therebetween and a bore 16 of the tubing string 12. The circulating valve controls flow between the bore 16 and the annulus 14. The circulating valve could be installed in a side pocket receptacle 20 of a side pocket mandrel 22 utilizing a kickover tool of the type disclosed in U.S. Pat. No. 3,876,001 to Goode, the entire disclosure of which is hereby incorporated by reference.
The circulating valve normally prevents flow between the bore 16 and annulus 14 through the ports 24 and 26 of the side pocket mandrel 22. However, when it is desired to provide circulation between the bore 16 and the annulus 14 through these ports, fluid pressure is exerted down the annulus 14 until a sufficient pressure differential exists across both valve plug means 36a and 36b from the annulus 14 to the bore 16. When a sufficiently high pressure differential has been obtained, frangible drawbar means 38 breaks. Both valve plug means 36a and 36b are blown into a position permitting flow between the tubing bore 16 and the annulus 14. FIG. 3 shows upper valve plug means 36a received within upper pocket means 70 and retained therein by retainer means 72 so that it is out of flow passage means permitting any condition of flow therethrough. FIG. 3 also shows lower valve plug means 36b received within lower pocket means 66 where it is also out of flow passage means permitting any condition of flow therethrough.
Once circulating valve 30 has been opened, any desired condition of flow between a tubing bore 16 and the annulus 14 may be created. For example, the well may be killed by injecting fluid down the annulus 14 through the first circulating port 24 of side pocket mandrel 22. From there one flow path will be established through the first circulating port means 50 of the circulating valve 30, the upper passage means 52a, second circulating port means 54, and into the side pocket receptacle 20 where it enters the bore 16. Another flow path will be established through first circulating port means 50, lower passage means 52b, third circulating port means 56, and through the second port means 26 into the bore 16. Thereafter, any desired operation may be performed on the well.
Once the desired operation has been performed, the circulating valve 30 is retrieved from the well. A kickover tool of the type disclosed in the aforementioned U.S. Pat. No.3,876,001 may be used to retrieve the circulating valve 30.
In FIGS. 4, 5, 6 and 7 a second embodiment of a circulating valve according to this invention is shown.
The circulating valve, generally indicated at 90, includes valve housing means 92, flow passage means defining two flow paths, two valve plug means 96a and 96b, and frangible drawbar means 98.
Valve housing means 92 is also adapted to be received within side pocket receptacle 20 and includes interconnected housing sections 92a, 92b, and 92c.
Two spaced seal means 100 and 102 surround valve housing means 92, defining a seal area 104 and an upper 106 and lower 108 end section of the valve housing means 92 to permit controlled flow of fluids through the circulating valve 90 when it is installed within a side pocket receptacle 20.
Flow passage means extends through valve housing means 92 and provides two flow paths, with one upper passage means 110 extending between first circulating port means 112 in the seal area 104 of valve housing means 92 and the upper end section 106 of valve housing means 92 and the other, lower passage means 114 extending between first circulating port means 112 and the lower end section 108 at second circulating port means 116. Both upper and lower passage means 110 and 114 include a reduced diameter, seal bore portion 117a and 117b, respectively.
An upper and lower valve plug means 96a and 96b, respectively, control fluid flow through the flow passage means by each controlling flow between first circulating port means 112 and a different end section of the valve 90. Each valve plug means 96a and 96b includes valve plug body means 118a and 118b and a circumferential seal 120a and 120b, respectively.
Frangible drawbar means 98 releasably maintains both valve plug means 96a and 96b in their initial position closing flow passage means and breaks upon a predetermined pressure differential across both valve plug means 96a and 96b to permit both valve plug means 96a and 96b to move to a position opening the flow passage means.
Lower pocket means 122 receives lower valve plug means 96b where it will be maintained out of the lower passage means 114 due to the force of gravity permitting any condition of flow. A bleed port 124 permits easy entry of the lower valve plug means 96b into the lower pocket means 122.
Upper valve plug means 96a is retained out of upper passage means 110 in an upper pocket means 126 in housing means 92.
The illustrated upper plug retainer means includes a plug retainer body means 128 disposed in the passage means 110. Plug retainer body means 128 and upper passage means 110 are adapted to permit flow through upper passage means 110 bypassing plug retainer body means 128. For example, as best seen in FIG. 6, plug retainer body means 128 may be an insert in upper passage means 110 having a square exterior configuration. Upper passage means 110 permits flow bypassing plug retainer body means 128 through the bore passages 110', 110", 110'", and 110"" left open between the square plug retainer body means 128 and the cylindrical housing means 92.
Upper pocket means 126 is formed within plug retainer body means 128 and opens into upper passage means 110. Upper pocket means 126 receives and retains upper valve plug means 96a after frangible drawbar means 98 breaks.
Upper valve plug means 96a is guided into upper pocket means 126 by a downward facing annular tapered surface 130. Once upper valve plug means 96a has entered upper pocket means 128, it is retained therein by an upward facing stop shoulder 132 above the annular tapered surface 130. Expandable and contractible means on upper valve plug means 96a permits it to enter upper pocket means 126 by contracting and once there expands to engage the shoulder 132 and thereby prevent upper valve plug means 96a from falling out of the upper pocket means 126. The preferred expandable and contractible means on upper valve plug means 96a is provided by circumferential seal 120a. Thus in addition to being sized so that seal 120a provides a seal between valve plug body means 118a and the wall of seal bore 117a, seal 120a is also sized so that it is contractible by tapered surface 130 to permit upper valve plug means 96a to enter upper pocket means 126 and once the valve plug means 96a is in upper pocket means 126, seal 120a is expandable to engage stop shoulder 132 to prevent upper valve plug means 96a from falling out of upper pocket means 126.
To facilitate ease of entry of upper valve plug means 96a into upper pocket means 126 a bleed port 134 is provided communicating between upper pocket means 126 and upper passage means 110. Additionally, fluid flowing in passage means 110 around the retainer body means 128 creates a lower pressure effect through bleed port 134 to maintain the upper valve plug means 96a within the upper pocket means 126 so that flowing fluids do not drive upper valve plug means 96a back into passage means 110.
The assembly and operation of the second embodiment of the circulating valve 90 are similar to the assembly and operation of the first embodiment of the circulating valve 30.
If desired only an upper passage means may be provided through valve housing means which would communicate between the seal area and the upper end section. Then the upper valve plug would be releasably maintained in an initial position blocking flow through the passage means by frangible drawbar means. Upon the application of a preselected pressure differential across upper valve plug means, frangible drawbar means would break and upper valve plug means would be blown into upper pocket means within valve housing means. There upper valve plug means would be retained, preferably out of the flow path through passage means, permitting any condition of flow through the circulating valve.
From the foregoing it can be seen that the objects of this invention have been obtained. A circulating valve for use in a well has been provided which permits twice the normal flow rate through the valve. An upper and lower valve plug control flow through the valve and when the valve is opened the upper valve plug is retained in a position where it is prevented from falling back into the flow path. Once the circulating valve is opened, any condition of fluid flow through the valve may be provided.
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.
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Disclosed is a circulating valve for use in a well. The circulating valve includes at least one valve plug initially blocking flow through the valve which moves to a retained position permitting flow through the valve upon the application of a predetermined pressure differential across the valve plug. This abstract is neither intended to define the scope of the invention, which, of course, is measured by the claims, nor is it intended to be limited in any way.
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RELATED APPLICATION DATA
This application is a Divisional application of U.S. patent application Ser. No. 08/962,214, filed Oct. 31, 1997, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to conformance additives, to conformance treatment fluids made therefrom, to methods of improving conformance in a well. In another aspect, the present invention relates to conformance additives comprising polymer and fibers, to conformance treatment fluids made therefrom, to methods of improving conformance in a well using such fluids.
2. Description of the Related Art
In the production of hydrocarbons from subterranean hydrocarbon bearing formations, poor vertical conformance results from the vertical juxtaposition of relatively high permeability geologic zones to relatively low permeability zones within the subterranean formation. Poor areal conformance results from the presence of high permeability streaks and high permeability anomalies within the formation matrix, such as vertical fractures and networks of the same, which have very high permeability relative to the formation matrix. Fluids generally exhibit poor flow profiles and sweep efficiencies in subterranean formations having poor vertical or areal conformance. Poor conformance is particularly a problem where vertical heterogeneity and/or fracture networks or other structural anomalies are in fluid communication with a subterranean wellbore across which fluids are injected or produced.
The prior art is replete with a number of attempts to remedy conformance problems. For example, U.S. Pat. Nos. 3,762,476; 3,981,363; 4,018,286; and 4,039,029 to Gall or Gall et al describe various processes wherein gel compositions are formed in high permeability zones of subterranean formations to reduce the permeability therein. According to U.S. Pat. No. 3,762,476, a polymer such as polyacrylamide is injected into a formation followed sequentially by a crosslinking agent. The sequentially injected slugs are believed to permeate the treatment zone of the formation and gel in situ.
U.S. Pat. Nos. 4,683,949 and 4,744,419 both to Sydansk et al., both note that it is generally held that effective polymer/crosslinking agent systems necessitate sequential injection of the gel components because gel systems mixed on the surface often set up before they can effectively penetrate the treatment region. Both Sydansk et al. patents further note that in practice, treatments such as that disclosed in U.S. Pat. No. 3,762,476 using sequentially injected gel systems have proven unsatisfactory because of the inability to achieve complete mixing and gelation in the formation. As a result, gels only form at the interface of the unmixed gel components and often in regions remote from the desired treatment region.
Both of the Sydansk et al. patents purport to overcome a then-existing need in the art for a gelation process capable of forming gels having a predetermined gelation rate, strength, and stability to satisfy the particular demands of a desired treatment region in a subterranean hydrocarbon-bearing formation, through the use of a high molecular weight water-soluble acrylamide polymer, a chromium III/carboxylate complex cross-linking agent.
U.S. Pat. No. 5,377,760 to Merrill notes that while the polymer system of Sydansk et al. '949 was an improvement over prior art systems which required sequential injection of the polymer components, difficulty was still encountered in employing the '949 polymer system to plug large fissures because the larger masses of polymer required often lack the necessary strength to resist the pressures to which they are exposed. Merrill proposes the incorporation of fibers in the polymer by mixing the fibers with the polymer solution at the surface.
U.S. Pat. No. 3,701,384 discloses a method of sealing thief zones in a subterranean formation by plugging pores with a solid material. A slurry of finely divided inorganic solids is injected into the formation together with an aqueous colloidal dispersion of a water-insoluble metal hydroxide in a dilute aqueous solution of a high-molecular-weight organic polymeric polyelectrolyte. The preferred polymer solution contains between about 0.01 and about 0.2 percent by weight of high molecular weight polyacrylamide or hydrolyzed polyacrylamide. At these concentrations, the dissolved polymer causes the suspended solids to flocculate, thereby blocking pores in the formation. The tested inorganic solids which interacted with the polymer solution to form strong solids included finely ground asbestos fibers and magnesium oxide. However, asbestos is undesirable for use today, due to its carcinogenicity.
Another approach taken by the prior art is to pump a slurry containing a mixture of flexible fibers and a bonding agent into highly permeable portions of a formation interval. An agent which precipitates or gels the bonding agent is then injected into the interval. The goal of the method is to build up a filter cake of fibers on the permeable formation as a result of the fibers being deposited out of the slurry as the slurry flows through, the permeable formation, and then bond the fibers of the filter cake in place. Examples of such a method are disclosed in U.S. Pat. Nos. 3,593,798, 3,949,811 and 3,462,958.
Larger fissures are bridged according to the disclosure of U.S. Pat. No. 2,708,973 by setting fibrous plants in place in the fissure, after which cement is added, thereby building on the framework of the plants. While such a method can bridge larger gaps, the process is impractical for use in deep formations that extend over a large area.
U.S. Pat. No. 3,374,834 discloses a method of stabilizing earth formations by injecting an aqueous solution of gelling material which contains finely divided inert solids and needle-like crystals of silicate materials which act as a suspending agent to prevent premature settling out of the solids. The resulting gel does not, however, provide the desired combination of strength, economy, ease of mixing and ability to be readily introduced into a formation.
However, in spite of the advancements in the prior art, there still need for further innovation in the conformance improvement arts.
Specifically, Merrill's teaching of mixing the fibers with the polymer solution requires a multiplicity of storage and mixing tanks, and a metering system which must be operated during the operation of the well. Specifically, a first tank will store a water and polymer solution, a second tank will store a water and cross-linking solution, and a third tank will be used to mix fibers with polymer solution from the first tank to create a polymer/fiber slurry. This polymer/fiber slurry is then metered from the third tank and combined with cross-linking solution metered from the second tank to the well bore.
Thus, there is a need for a conformance additive which would allow for simplification of the mixing equipment.
There is another need a conformation method allowing for a simplification of the mixing equipment.
These and other needs in the art will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide for further innovation in the conformance improvement arts.
It is another object of the present invention to provide for a conformance additive which will allow for the simplification of the mixing equipment.
It is even another object of the present invention to provide for a conformance method will allow for the simplification of the mixing equipment.
These and other objects of the present invention will become apparent to those of skill in the art upon review of this specification, including its drawings and claims.
According to one embodiment of the present invention there is provided a conformance additive comprising a dry mixture of water soluble crosslinkable polymer, a crosslinking agent, and a reinforcing material selected from among fibers and comminuted plant materials. In preferred embodiments, polymer is an a carboxylate-containing polymer and the crosslinking agent is a chromic carboxylate complex. In other preferred embodiments, the reinforcing material may comprise hydrophobic fibers selected from among nylon, rayon, and hydrocarbon fibers, and/or hydrophilic fibers selected from among glass, cellulose, carbon, silicon, graphite, calcined petroleum coke, and cotton fibers. The comminuted plant material is selected from the group of comminuted plant materials of nut and seed shells or hulls of almond, brazil, cocoa bean, coconut, cotton, flax, grass, linseed, maize, millet, oat, peach, peanut, rice, rye, soybean, sunflower, walnut, and wheat; rice tips; rice straw; rice bran; crude pectate pulp; peat moss fibers; flax; cotton; cotton linters; wool; sugar cane; paper; bagasse; bamboo; corn stalks; sawdust; wood; bark; straw; cork; dehydrated vegetable matter; whole ground corn cobs; corn cob light density pith core; corn cob ground woody ring portion; corn cob chaff portion; cotton seed stems; flax stems; wheat stems; sunflower seed stems; soybean stems; maize stems; rye grass stems; millet stems; and mixtures thereof.
According to another embodiment of the present invention, there is provided a method of forming a conformance fluid. The method generally includes taking the above conformance additive and contacting it with water or other aqueous solution.
According to even another embodiment of the present invention, there is provided a method of for plugging an opening in a subterranean formation. The method generally includes contacting the above described conformance additive with water or an aqueous solution to for a conformance fluid. The method then includes injecting the conformance fluid into the formation.
These and other embodiments of the present invention will become apparent to those of skill in the art upon review of this specification and claims.
DETAILED DESCRIPTION OF THE INVENTION
The conformance additive of the present invention includes polymer, cross-linking agent and either fibers or comminuted particles of plant materials. In a preferred embodiment of the present invention, the conformance additive is a dry mixture of polymer, cross-linking agent and either fibers or comminuted particles of plant materials.
Any suitable relative amounts of the polymer, cross-linking agent and either fibers or comminuted particles of plant materials may be utilized in the present invention provided that the desired conformance results are achieved. Generally, the fibers or comminuted particles will comprise in the range of about 1 to about 99 weight percent, preferably in the range of about 25 to about 90 weight percent, more preferably in the range of about 50 to about 80 weight percent, and even more preferably in the range of about 70 to about 75 weight percent, all based on the total with of the polymer, fibers and particles. A suitable amount of crosslinking agent is provided to reach the desired amount of crosslinking. Suitable amounts of dispersants, retarders, accelerants, and other additives may be provided as necessary or desired.
The polymer utilized in the practice of the present invention is preferably water soluble and must be capable of being pumped as a liquid and subsequently crosslinked in place to form a substantially non-flowing crosslinked polymer which has sufficient strength to withstand the pressures exerted on it. Moreover, it must have a network structure capable of incorporating reinforcing fibers.
While any suitable water soluble polymer may be utilized, the preferred polymer utilized in the practice of the present invention is a carboxylate-containing polymer. This preferred carboxylate-containing polymer may be any crosslinkable, high molecular weight, water-soluble, synthetic polymer or biopolymer containing one or more carboxylate species.
For an example of polymers and crosslinking agents suitable for use herein and details regarding their making and use, please see U.S. Pat. Nos. 4,683,949 and 4,744,419, both incorporated herein by reference.
The average molecular weight of the carboxylate-containing polymer utilized in the practice of the present invention is in the range of about 10,000 to about 50,000,000, preferably in the range of about 100,000 to about 20,000,000, and most preferably in the range of about 200,000 to about 15,000,000.
Biopolymers useful in the present invention include polysaccharides and modified polysaccharides. Non-limiting examples of biopolymers are xanthan gum, guar gum, carboxymethylcellulose, o-carboxychitosans, hydroxyethylcellulose, hydroxypropylcellulose, and modified starches. Non-limiting examples of useful synthetic polymers include acrylamide polymers, such as polyacrylamide, partially hydrolyzed polyacrylamide and terpolymers containing acrylamide, acrylate, and a third species. As defined herein, polyacrylamide (PA) is an acrylamide polymer having substantially less than 1% of the acrylamide groups in the form of carboxylate groups. Partially hydrolyzed polyacrylamide (PHPA) is an acrylamide polymer having at least 1%, but not 100%, of the acrylamide groups in the form of carboxylate groups. The acrylamide polymer may be prepared according to any conventional method known in the art, but preferably has the specific properties of acrylamide polymer prepared according to the method disclosed by U.S. Pat. No. Re. 32,114 to Argabright et al incorporated herein by reference.
Any crosslinking agent suitable for use with the selected polymer may be utilized in the practice of the present invention. Preferably, the crosslinking agent utilized in the present invention is a chromic carboxylate complex.
The term “complex” is defined herein as an ion or molecule containing two or more interassociated ionic, radical or molecular species. A complex ion as a whole has a distinct electrical charge while a complex molecule is electrically neutral. The term “chromic carboxylate complex” encompasses a single complex, mixtures of complexes containing the same carboxylate species, and mixtures of complexes containing differing carboxylate species.
The chromic carboxylate complex useful in the practice of the present invention includes at least one or more electropositive chromium III species and one or more electronegative carboxylate species. The complex may advantageously also contain one or more electronegative hydroxide and/or oxygen species. It is believed that, when two or more chromium III species are present in the complex, the oxygen or hydroxide species may help to bridge the chromium III species. Each complex optionally contains additional species which are not essential to the polymer crosslinking function of the complex. For example, inorganic mono- and/or divalent ions, which function merely to balance the electrical charge of the complex, or one or more water molecules may be associated with each complex. Non-limiting representative formulae of such complexes include:
[Cr 3 (CH 3 CO 2 ) 6 (OH) 2 ] 1+ ;
[Cr 3 (CH 3 CO 2 ) 6 (OH) 2 ]NO 3 ·6H 2 O;
[Cr 3 (CH 3 CO 2 ) 6 (OH) 2 ] 3+ ; and
[Cr 3 (CH 3 CO 2 ) 6 (OH) 2 ](CH 3 CO 2 ) 3 ·H 2 O.
“Trivalent chromium” and “chromic ion” are equivalent terms encompassed by the term “chromium III” species as used herein.
The carboxylate species are advantageously derived from water-soluble salts of carboxylic acids, especially low molecular weight mono-basic acids. Carboxylate species derived from salts of formic, acetic, propionic, and lactic acid, substituted derivatives thereof and mixtures thereof are preferred. The preferred carboxylate species include the following water-soluble species: formate, acetate, propionate, lactate, substituted derivatives thereof, and mixtures thereof. Acetate is the most preferred carboxylate species. Examples of optional inorganic ions include sodium, sulfate, nitrate and chloride ions.
A host of complexes of the type described above and their method of preparation are well known in the leather tanning art. These complexes are described in Shuttleworth and Russel, Journal of the Society of Leather Trades' Chemists, “The Kinetics of Chrome Tannage Part I.,” United Kingdom, 1965, v. 49, p. 133-154; “Part III.,” United Kingdom, 1965, v. 49, p. 251-260; “Part IV.,” United Kingdom, 1965, v. 49, p. 261-268; and Von Erdman, Das Leder, “Condensation of Mononuclear Chromium (III) Salts to Polynuclear Compounds,” Eduard Roether Verlag, Darmstadt Germany, 1963, v. 14, p. 249; and incorporated herein by reference. Udy, Marvin J., Chromium. Volume 1: Chemistry of Chromium and its Compounds. Reinhold Publishing Corp., N.Y., 1956, pp. 229-233; and Cotton and Wilkinson, Advanced Inorganic Chemistry 3rd Ed., John Wiley and Sons, Inc., N.Y., 1972, pp. 836-839, further describe typical complexes which may be within the scope of the present invention and are incorporated herein by reference. The present invention is not limited to the specific complexes and mixtures thereof described in the references, but may include others satisfying the above-stated definition.
Salts of chromium and an inorganic monovalent anion, e.g., CrCl3, may also be combined with the crosslinking agent complex to accelerate gelation of the polymer solution, as described in U.S. Pat. No. 4,723,605 to Sydansk, which is incorporated herein by reference.
The molar ratio of carboxylate species to chromium III in the chromic carboxylate complexes used in the process of the present invention is typically in the range of 1:1 to 3.9:1. The preferred ratio is range of 2:1 to 3.9:1 and the most preferred ratio is 2.5:1 to 3.5:1.
The additive of the present invention may comprise fibers or comminuted particles of plant materials, and preferably comprises comminuted particles of one or more plant materials.
Fibers suitable for use in the present invention are selected from among hydrophilic and hydrophobic fibers. Incorporation of hydrophobic fibers will require use of a suitable wetting agent. Preferably, the fibers utilized in the present invention comprise hydrophilic fibers, most preferably both hydrophilic and hydrophobic fibers.
With respect to any particular fiber employed in the practice of the present invention, it is believed that the longer the fiber, the more difficult it is to be mixed uniformly in solution. It is believed that fibers as long as 12,500 microns may tend to aggregate and form clumps. The shorter the fiber, it is believed the easier it is to mix in solution. On the other hand, the shorter the fiber, the greater the quantity necessary to provide the desired level of strength in a reinforced mature gel. In general, the fibers utilized in the present invention will have a length in the range of 100 microns to 3200 microns, preferable 100 microns to 1000 microns.
Non-limiting examples of suitable hydrophobic fibers include nylon, rayon, hydrocarbon fibers and mixtures thereof.
Non-limiting examples of suitable hydrophilic fibers include glass, cellulose, carbon, silicon, graphite, calcined petroleum coke, cotton fibers, and mixtures thereof.
Non-limiting examples of comminuted particles of plant materials suitable for use in the present invention include any derived from: nut and seed s hells or hulls such as those of peanut, almond, brazil, cocoa bean, coconut, cotton, flax, grass, linseed, maize, millet, oat, peach, peanut, rice, rye, soybean, sunflower, walnut, wheat; various portions of rice including the rice tips, rice straw and rice bran; crude pectate pulp; peat moss fibers; flax; cotton; cotton linters; wool; sugar cane; paper; bagasse; bamboo; corn stalks; various tree portions including sawdust, wood or bark; straw; cork; dehydrated vegetable matter (suitably dehydrated carbonhydrates such as citrus pulp, oatmeal, tapioca, rice grains, potatoes, carrots, beets, and various grain sorghams) whole ground corn cobs; or various plant portions the corn cob light density pith core, the corn cob ground woody ring portion, the corn cob coarse or fine chaff portion, cotton seed stems, flax stems, wheat stems, sunflower seed stems, soybean stems, maize stems, rye grass stems, millet stems, and various mixtures of these materials.
Optionally a dispersant for the comminuted plant material in the range of about 1 to about 20 pounds, preferably in the range of about 5 to about 10 pounds, and more preferably in the range of about 7 to about 8 pounds of dispersant may be utilized per pound of comminuted plant material. A non-limiting example of a dispersant would be NaCl.
Preferred comminuted materials useful in the practice of the present invention include those derived from peanuts, wood, paper any portion of rice seed or plant, and any portion of corn cobs.
These various materials can be comminuted to very fine particle sizes by drying the products and using hammer mills, cutter heads, air control mills or other comminution methods as is well known to those of skill in the comminution art. Air classification equipment or other means can be used for separation of desired ranges of particle sizes using techniques well-known in the comminution art.
Any suitable size of comminuted material may be utilized in the present invention, along as such size produces results which are desired. Of course, the particle size will be a function of diameter of the porosity passages. While the present invention will find utility for passages on the order of microns in diameter, it will also find utility on larger passages, for example, those with diameters greater than {fraction (1/64)}, {fraction (1/16)} or event ⅛ of an inch.
In most instances, the size range of the comminuted materials utilized herein will range from below about 8 mesh (“mesh” as used herein refers to standard U.S. mesh), preferably from about −65 mesh to about −100 mesh, and more preferably from about −65 mesh to about −85 mesh. Specifically preferred particle sizes for some materials are provided below.
Preferred mixtures of comminuted materials useful in the practice of the present invention include a rice fraction and peanut hulls; a rice fraction and wood fiber and/or almond hulls; a rice fraction and a corn cob fraction, preferably a chaff portion; and a corn cob fraction, preferably a pith or chaff portion, a rice fraction, and at least one of wood fiber, nut shells, paper and shredded cellophane.
Rice is commercially available in the form of rice hulls, rice tips, rice straw and rice bran, as these various parts of the rice plant are separated commercially and are widely available from rice mills. Preferably, the size range of the rice fraction utilized herein will range from below about 8 mesh (“mesh” as used herein refers to standard U.S. mesh), preferably from about −65 mesh to about −100 mesh, and more preferably from about −65 mesh to about −85 mesh.
After the corn kernals are removed, corn cobs consist of four principle parts that are arranged concentrically. The central portion is a very light density pith core, that is surrounded by a woody ring, that in turn is surrounded by a coarse chaff portion, that in turn is covered by a fine chaff portion. The coarse and fine chaff portions form the sockets for ancoring the corn kernels to the corncob. The normal methods of grinding corncobs produce a mixture of all four parts enumerated above. It is possible, however, to separate the woody ring material from the remainder of the cob. The chaff portion of the corncob remaining after removal of the woody ring material is known as “bees wings”. In the present invention, any of the pith or chaff portions(“BPC”) are the preferred portions of the corn cob, with the chaff portions being more preferred. A range of particle sizes of pith and chaff can be obtained from comminution, but the size range smaller than about 8 mesh is suitable for this invention. Preferably, a particle size distribution ranging from smaller than 8 mesh to smaller than 100 mesh is utilized.
Preferred woods for use as comminuted materials in the present invention include any type of hard wood fiber, including cedar fiber, oak fiber, pecan fiber and elm fiber. Preferably the wood fiber comprises cedar fibers.
Preferred nut shells for use in the present invention include pecan, walnut, and almond. Preferably, the nut shells comprise at least one of pecan or walnut shells.
Preferred particle sizes for the wood fibers, nut shells, paper and cellophane will generally range from about +10 mesh to −100 mesh. An illustration of a non-limiting particle size distribution for these materials would include particles of +10 mesh, +20 mesh, +30 mesh, +50 mesh, +60 mesh, +100 mesh, and −100 mesh.
For one of the preferred comminuted plant mixtures comprising a corn cob fraction, a rice fraction, and at least one of wood fiber, nut shells, paper and shredded cellophane, the mixture will generally comprise in the range of about 5 to about 95 weight percent rice, in the range of about 5 to about 95 weight percent corncob pith or chaff, with the total of ground wood fiber, ground nut shells, ground paper and shredded cellophane comprising in the range of about 5 to about 95 weight percent (weight percent based on the total weight of plant material in the mixture. Preferred ranges are about 20 to about 75 weight percent rice, about 5 to about 35 weight percent corncob pith or chaff, with the total of ground wood fiber, ground nut shells, ground paper and shredded cellophane comprising in the range of about 20 to about 75 weight percent. More preferred ranges are about 30 to about 50 weight percent rice, about 10 to about 30 weight percent corncob pith and chaff, with the total of ground wood fiber, ground nut shells, ground paper and shredded cellophane comprising in the range of about 25 to about 50 weight percent.
As these comminuted materials are to be added to a water base conformance fluid, a small amount of oil may optionally added to the mixture. This optional oil is preferably added while the plant materials are being mixed together. This mixing may take place in a ribbon blender, where the oil in the required amount is applied by a spray bar. The oil wets the particles and adds to their lubricity while at the same time helping to control dust produced by the mixing operation. A variety of oils may be utilized in the practice of the present invention in concentrations generally ranging from about 1 percent to about 5 percent by weight based on the total weight of the mixture of comminuted materials, more preferably ranging from about 1 percent to about 2 percent. A non-limiting example of a commercially available oil suitable for use in the present invention includes ISOPAR V, available from Exxon Corporation.
The various components of the present invention may be mixed in any suitable order utilizing mixing techniques as known to those in the art, including dry mixing of the various components prior to addition to water, or alternatively, either or both of the polymer and cross-linking agent may be utilized as a solution. Most preferably, the various components are mixed in dry form, and then contacted with water or aqueous solution to form a conformance fluid. This conformance fluid is then injected into the well as is known in the art.
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as equivalents thereof by those skilled in the art to which this invention pertains.
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For conformance treatment to plug an opening in subterranean hydrocarbon bearing formation, a conformance additive including a dry mixture of water soluble crosslinkable polymer, a crosslinking agent, and a reinforcing material of fibers and/or comminuted plant materials. The method of forming a conformance fluid includes contacting the additive with water or an aqueous solution, with a method of conforming the formation further including the step of injecting the fluid into the formation to plug the opening.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vertical furnace used in the fabrication of semiconductor devices, and more particularly, to a single bodied cap for a vertical furnace which supports a semiconductor wafer boat and maintains an appropriate temperature in the vertical furnace.
2. Description of the Related Art
Various films, such as polysilicon, oxide, and nitride films, are formed in a furnace in order to manufacture semiconductor devices. The furnace should be extremely stable and have a high degree durability since combustible poisonous gases are used at high temperatures to form the various films therein. The furnace should also prohibit the generation of contaminating particles, and the parts of the furnace should be easily changeable after installation of the furnace.
In particular, since the cap for supporting the boat on which wafers are loaded is also the portion through which reactive gases are initially passed, the cap itself should not contain any contaminating particles, should be durable, and should be easy to assemble and replace.
FIG. 1 is a perspective view of a furnace in which a conventional cap is used. FIG. 2 is an exploded perspective view of the main portions of the furnace of FIG. 1. Referring to FIGS. 1 and 2, the furnace comprises a cap 12, a holder 18, and a base 20 on which the cap 12 is mounted. A boat 10, into which wafers 11 are placed, is composed of two parallel circular plates 10b and 10c connected by a plurality of supporting rods 10a, and two connection holes 10d formed in the lower circular plate 10c for connecting the boat 10 to the cap 12.
The cap 12 supports the boat 10 and has a cylindrical structure having an open bottom. At the upper surface of the cap 12, screw holes 12a are formed, corresponding to the connection holes 10d of the lower circular plate 10c. The boat 10 and the cap 12 are connected via screws 14 through the connection holes 10d and screw holes 12a.
The holder 18, within which a plurality of adiabatic plates 16 are stacked side by side, has a similar structure to that of the boat 10 and fits inside the cap 12 after the adiabatic plates 16 have been placed therein. A through hole 18b for connecting the holder to the base 20 is formed in the lower circular plate 18a of the holder 18. The adiabatic plates 16 maintain a uniform temperature inside the heat treatment tube 24.
The base 20 comprises a flanged supporting portion 20b, a projecting portion 20a at the center of the flanged supporting portion 20b for connecting the base 20 to the holder 18, and a tube supporting portion 20c, having a diameter larger than that of the heat treatment tube 24, to support the heat treatment tube 24 placed thereon.
The tube supporting portion is connected to an elevating means 22. The elevating means 22 is, for example, a hydraulic jack, for raising the boat 10 into the heat treatment tube 24.
In the conventional vertical furnace described above, the means for supporting the boat 10 and maintaining an appropriate temperature for the reaction of gases comprises three main parts, i.e., the cap 12, the holder 18, and the adiabatic plates 16. Since the respective parts are formed of quartz, however, the friction generated among the respective parts during the assembly process may cause a crack or destroy any one of the parts. In addition, the fine quartz powder generated during the assembly process may become a contaminant during subsequent diffusion or deposition manufacturing processes.
Another disadvantage is that since the cap 12 is tightly closed, some of the reactive gases supplied to the inside of the heat treatment tube 24 rise along the narrow spaces between the cap 12 and the heat treatment tube 24 and reach the lower portion of the boat 10, forming an open space. Other reactive gases that rise rapidly flow to the upper portion of the boat 10, forming a vortex by spreading rapidly into the open space of the lower portion of the boat.
Thus, the flow of the reactive gases on the surfaces of the wafers is not uniform and will vary depending on the respective positions of the wafers inside the boat 10. Also, non-activated gases can act as contaminating particles on the wafers. Such problems are more severe at the lower portions of the boat.
Moreover, there are many problems in maintaining the parts of the furnace since the durability of the respective parts will vary and the procedures for replacing the parts are complicated.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a single bodied cap for a vertical furnace which supports a boat and maintains an appropriate temperature in the vertical furnace.
To achieve these and other objects, there is provided a cap for a vertical furnace, comprising: a first flat plate; a second flat plate parallel to the first flat plate and separated therefrom by a first predetermined distance; a plurality of support rods connecting the first flat plate to the second flat plate; and a plurality of adjacent and horizontally disposed adiabatic plates that are vertically stacked between the first and the second flat plates such that edges of the adiabatic plates contact the support rods, the adjacent adiabatic plates being separated by a second predetermined distance, wherein the first and the second flat plates, the adjacent adiabatic plates, and the plurality of support rods are integrally formed in a single structure.
It is preferable that the respective adjacent adiabatic plates have a plurality of openings formed therein, and further, that the openings are offset from the next adjacent adiabatic plate.
In another embodiment, it is preferable that the adiabatic plates are configured with a hollow central portion that is maintained in a vacuum state.
The first flat plate may have screw holes formed therethrough, or projecting portions on an upper surface, for connection to a wafer boat. The second flat plate may have a central opening formed therethrough, or a central groove formed at a lower surface, for connection to a base support member.
The first and the second flat plates, the adiabatic plates, and the support rods are each respectively formed of quartz or SiC.
In the cap for the vertical furnace described above, the parts for supporting the boat and maintaining an appropriate temperature are encompassed in one body. Therefore, since assembly of the respective parts is not required, the conventional problem of instability due to contaminating particles being generated in the assembly process is avoided, and the installation, management, and replacement of the device is simplified.
BRIEF DESCRIPTION OF THE DRAWINGS
The above objects and advantages of the present invention will become more apparent by describing in detail a preferred embodiment thereof with reference to the attached drawings in which:
FIG. 1 is a perspective view of a vertical furnace in which a conventional cap is used;
FIG. 2 is an exploded perspective view of the main portions of the vertical furnace shown in FIG. 1;
FIG. 3 is a perspective view of the cap for the vertical furnace according to an embodiment of the present invention;
FIG. 4 is a sectional view taken along the IV--IV line of FIG. 3;
FIG. 5 is a sectional view of an alternate embodiment of the lower flat plate of the present invention;
FIG. 6 is a sectional view of an alternate embodiment of the upper flat plate of the present invention;
FIG. 7 is a sectional view of an alternate embodiment of the adiabatic plates of the present invention;
FIG. 8 is a sectional view of an another alternate embodiment of the adiabatic plates of the present invention;
FIG. 9 is a schematic sectional diagram of the vertical furnace in which the cap of FIG. 3 is installed; and
FIG. 10 is a bar graph comparing the number of the contamination particles generated in a vapor deposition film formed in a vertical furnace having the cap according to the present invention installed, with the number of the contamination particles generated in a vapor deposition film formed in a vertical furnace having a conventional cap installed.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, preferred embodiments of a cap for a furnace according to the present invention will be described in detail with reference to FIGS. 3 through 9.
FIG. 3 is a perspective view of a cap 30 according to a preferred embodiment of the present invention and FIG. 4 is a sectional view taken along the IV--IV line of FIG. 3. Referring to FIGS. 3 and 4, the cap 30 comprises an upper flat plate 31 and a lower flat plate 32, where the upper and lower flat plates 31 and 32 are connected by a plurality of support rods 33. The cap 30 has a plurality of adiabatic plates 34, stacked parallel in a side by side vertical orientation. The adiabatic plates 34 are spaced at equidistant intervals, and the edges of the adiabatic plates 34 contact the support rods 33. The upper flat plate 31 connects to a wafer boat 10 (see FIG. 9) and the lower flat plate 32 connects to a supporting portion 20b (see FIG. 9) of a base 20. The upper flat plate 31, the lower flat plate 32, the support rods 33, and the adiabatic plates 34 are connected to form a single body or single structure and are preferably formed of quartz or SiC.
As shown in FIG. 3, in the upper flat plate 31, two screw holes 31a are preferably formed for connecting the upper flat plate 31 to the boat 10 with screws 14 (see FIG. 9). In the lower flat plate 32, a central opening 32a is formed for connecting the cap 30 to the projecting portion 20a (see FIG. 9) of the base 20.
According to the above embodiment, the cap 30 of the present invention does not need to be assembled since the cap 30 is comprised of a single body, unlike the conventional cap. Therefore, no contamination particles are generated due to the friction caused during assembly, and the single structure cap is easily installed and replaced.
FIG. 5 is a sectional view showing another embodiment of the lower flat plate 52 of the cap 30 according to the present invention. The lower flat plate 52 shown in FIG. 5 is different from the lower flat plate 32 shown in FIG. 4 in that a groove 52a is formed along the lower surface of the plate 32, instead of the central opening 32a, for connecting the cap 30 to the projecting portion 20a of the base 20. Since the groove 52a is formed instead of the central opening 32a, the intrusion of contaminants inside the cap 30 from the base 20 through the central opening 32a of the lower flat plate 32 is prevented during the formation of the vapor deposition film.
FIG. 6 is a sectional view of an upper flat plate 61 for the cap 30 according to another embodiment of the present invention. Rather than having screw holes 31a (see FIG. 4), the upper flat plate 61 shown in FIG. 6 has two projecting portion 61a for connecting the upper flat plate 61 to the boat 10. Since the projecting portion 61a are directly inserted into the connection holes 10d of the boat 10, screws 14 are not required and the assembly is simplified. Also, contamination particles generated in the process of driving the screws 14 are eliminated.
FIG. 7 is a partial sectional view showing another embodiment of the adiabatic plates residing in the cap 30 according to the present invention. The adiabatic plates 74 shown in FIG. 7 have a plurality of openings 74a formed therein. In particular, the openings 74a of the adiabatic plates 74 are arranged so that openings 74a of adjacent plates are offset from each other. By forming the openings 74a in the adiabatic plates 74 in such a manner, the heat flows through the cap and the furnace easily.
FIG. 8 is a sectional view illustrating the adiabatic plates of the cap 30 according to still another embodiment of the present invention. The adiabatic plates 84 of FIG. 8 have hollow central portions 84a that are maintained in a vacuum state. Due to these inner vacuum spaces 84a, the temperature between the adiabatic plates 84 can be kept uniform to maximize the adiabatic effect of the cap 30.
FIG. 9 is a sectional view of the vertical furnace in which the cap 30 of FIG. 3 is installed. As shown in FIG. 9, the heat treatment tube 24 is comprised of two tubes, i.e., the outer tube 24a and the inner tube 24b. The opening of the outer tube 24a fits on the tube supporting portion 20c of the base 20. The outer tube 24a of the heat treatment tube 24 contacts and seals to the tube supporting portion 20c to prevent gases from escaping. The cap 30 is placed on the supporting portion 20b of the base 20 inside the heat treatment tube 24. The boat 10, into which wafers 11 are loaded, is placed on the cap 30. A gas supply pipe 61 from a gas control unit 60, and an exhaust pipe 63 connected to an outlet 62, are respectively connected to the heat treatment tube 24.
The operation of the furnace will be described with reference to FIG. 9. The cap 30 and the boat 10 are lifted into a predetermined position inside the heat treatment tube 24 by the operation of the elevating means 22 which is connected to the base 20. Thus, the lower rim of the outer tube 24a opening contacts the tube supporting portion 20c of the base.
Then, reactive gases for forming the vapor deposition film are supplied from the gas control unit 60 to the inside of the heat treatment tube 24 through the gas supply pipe 61. The gases flow around the surfaces of the wafers 11 loaded in the boat 10 as indicated by the direction of the arrows in FIG. 9, thereby forming the vapor deposition film on the wafer 11.
Since the cap 30 has an open structure, such that the flow of gases in and out are facilitated, the gases supplied from the gas supply pipe 61 pass through the inside of the cap 30. Therefore, the reactive gases reach the surfaces of the wafers 11 in the boat 10 after activation of the gases has been accomplished, thereby reducing the number of contamination particles generated, and the vapor deposition film is uniformly formed on the surfaces of the wafers 11 regardless of the position of the wafer 11 in the boat 10. In effect, the cap 30 performs a function similar to that of using dummy wafers.
To measure the effects of using the cap 30 according to the present invention, the number of contamination particles generated at three sections of the boat 10, i.e., an upper portion, a middle portion, and a lower portion, are shown in Table 1, after forming a nitride film (Si 3 N 4 ) to a thickness of 1500 Å in the furnace as shown in FIG. 9. To compare the results of using the cap 30 of the present invention with that of the conventional cap, the number of the contamination particles generated in the furnace as shown in FIG. 1 under the same experiments conditions were measured.
FIG. 10 is a bar graph comparing the average number of contamination particles generated in a vapor deposition film formed in a vertical furnace having a cap installed according to the present invention (hashed bars), with the average number of the contamination particles generated in a vapor deposition film formed in a vertical furnace having a conventional cap installed (clear bars).
TABLE 1______________________________________Number of Contamination Particles Number of contamination particles generated Number of contamination using the cap particles generated of the present invention using a conventional capExperiment Lower Middle Upper Lower Middle UpperNo. Portion Portion Portion Portion Portion Portion______________________________________1 25 11 12 501 355 392 38 26 15 300 300 763 41 25 18 528 246 4164 84 26 12 725 303 2105 23 18 7 300 224 1056 30 27 15 355 173 2327 29 20 17 364 104 898 71 25 19 279 57 899 42 28 41 715 545 13910 52 29 27 294 73 121Average 44 24 18 436 238 152______________________________________
As shown in Table 1 and FIG. 10, as a result of using the cap according to the present invention, the number of contamination particles decreases remarkably, compared with the number of contamination particles generated using the conventional cap. Also, the results also suggest that the reactions take place uniformly, regardless of the position of the wafers 11 inside the boat 10.
The single body cap of the present invention has several advantages. First, the cap does not require repeated assembly and disassembly since the parts for supporting the boat and maintaining the temperature are encompassed in one body. Therefore, the operating rate of the furnace is enhanced since time is saved in installing the cap. Also, maintaining and replacing the cap can be accomplished efficiently.
Another advantage is that the operation of the furnace is stabilized using the cap of the present invention since contamination by quartz powders generated by the conventional friction and cracking of the respective parts during the assembly process is prevented. Also, since the cap itself has an open structure in which reactive gases flow easily and are fully activated, the reactive gases flow evenly over the surfaces of the wafers loaded in the boat, thereby allowing a uniform film to be formed.
While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiment, but, on the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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A cap for a vertical furnace includes a first flat plate and a second flat plate separated by a predetermined distance, and a plurality of support rods connecting the first and second flat plates. A plurality of adjacent and horizontally disposed adiabatic plates are vertically stacked between the first and the second flat plates such that edges of the adiabatic plates contact the support rods. The first and second flat plates, adjacent adiabatic plates, and the plurality of support rods are integrally formed in a single structure. Since all the components of the cap are formed in single structure, installation and replacement is simplified and the generation of contamination particles is prevented since no parts need to be repeatedly assembled and disassembled.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention provides a means of modifying the flow of air into a combustion apparatus. Specifically, it provides a means of modifying the location of the airflow within the apparatus.
2. Description of the Prior Art
Past practice has most commonly been to fix the location of an air supply within a combustion apparatus, and to provide a means of modifying the rate of airflow into the apparatus. This practice is especially well suited for use when the type of fuel and depth of fuel bed remain constant or nearly so.
One typical air supply arrangement furnishes primary combustion air at a certain depth below the top of the fuel bed, usually through a grate. Secondary air is supplied to the fire at a certain height above the top of the fuel bed. The depth of the primary air supply and the height of the secondary air supply are established so as to provide maximum efficiency at the design rate of burning. The fuel bed depth is maintained constant by a continuous fuel-loading mechanism.
When the type of fuel and/or depth of fuel bed are subject to change, a means of modifying the location of the airflow within the combustion apparatus is sometimes desirable. Several prior inventions provide such means; however, the present invention offers an original mechanism which is especially well-suited for certain uses, as should become apparent from the description below.
SUMMARY OF THE INVENTION
In its simplest form, the invention consists of one fixed surface containing a slot and one movable surface containing another slot. Air is supplied to a combustion apparatus through the intersection of the two slots. The location of this intersection is changed by movement of the movable surface.
When applied to the typical air supply arrangement described above, this mechanism allows the depth of the primary air supply below the top of the fuel bed to be varied so as to provide best efficiency for different fuels and firing rates. A duplicate mechanism allows the height of the secondary air supply above the top of the fuel bed to be varied for the same reason. Furthermore, the depth of the fuel bed may be allowed to change while maintaining the depth of the primary air supply and the height of the secondary air supply constant with respect to the top of the fuel bed. Thus, fuel may be batch-loaded into a combustion apparatus so that the top of the fuel bed is near the top of the apparatus, and may then be burned without replenishment so that the top of the fuel bed is continuously lowered; during this burning process, the depth of the primary air supply and the height of the secondary air supply may be maintained constant with respect to the top of the fuel bed. In this manner, fuel may be burned in a batch-loaded combustion apparatus with the same efficiency that is obtained in a continuously-loaded apparatus. Much of the fuel-handling equipment normally associated with a combustion apparatus may be eliminated, resulting in a smaller and simpler installation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the simplest embodiment of the invention, wherein the fixed and movable surfaces are flat. Air plenum 1 is separated from combustion zone 2 by fixed surface 3 containing slot 4, and by movable surface 5 containing slot 6. Slot 6 is constructed at an angle to slot 4. Air passes from plenum 1 to combustion zone 2 through the intersection of slots 6 and 4. The location of this intersection may be adjusted by transverse movement of surface 5. Arrows on the figure indicate the flow of air.
FIGS. 2 and 3 show a variation wherein the fixed and movable surfaces are of tubular construction. This is the preferred embodiment.
FIG. 4 shows the addition of a second movable surface to extend the range of adjustment.
FIGS. 5, 6 and 7 show the use of discrete holes rather than slots in the various surfaces.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment, the fixed and movable surfaces are of tubular construction.
FIG. 2 shows slot 7 parallel to axis of fixed tube 8, and slot 9 in spiral relation to the axis of movable tube 10. Tube 10 is of such a size as to fit snugly inside tube 8. Rotation of tube 10 inside tube 8 changes the location of the intersection of slots 7 and 9. Holes 11 and 11' allow free communication of air from the outside of tube 8 to the inside of tube 10 throughout the range of rotation of tube 10. The top of tube 8 is sealed, and the bottom of tube 10 is sealed. Sealing means is provided to prevent air leakage between tube 8 and tube 10 below holes 11. Grease applied to the cross-hatched area of tube 10, at the right side of FIG. 2, provides adequate sealing means for low pressure use. Supporting means, not shown, is provided to prevent air pressure from forcing tube 10 out of tube 8.
Air supplied to plenum 12 passes through holes 11 and 11' to the inside of tube 10, and then out through the intersection of slots 7 and 9 to combustion zone 14. Similarly, air supplied to plenum 13 passes through holes 11" in tube 8' to the inside of tube 10', and then out through the intersection of slots 7' and 9' to combustion zone 14. In the example shown, plenum 12 supplies primary combustion air, and plenum 13 supplies secondary air. The volume of air supplied to each plenum may be independently varied. Arrows on the figure indicate the flow of air. In FIG. 3, the use of multiple tubular assemblies is illustrated.
FIG. 4 shows tubes 15 and 16, corresponding respectively to tubes 8 and 10 of FIG. 2. Slots 17 and 18 correspond respectively to slots 7 and 9; however, slots 17 and 18 are of such a length as to intersect twice, whereas slots 7 and 9 intersect only once. Tube 19, containing offset slot 20, may be interposed between tubes 15 and 16, covering one of the intersections. In the case illustrated, the upper intersection is covered, and air flows through the lower intersection. A simple rotation of tube 19 will cover the lower intersection, and allow air to flow through the upper intersection. Proper manipulation of tubes 16 and 19 will allow the position of the uncovered intersection to be continuously varied over the full length of slot 17. In this construction, tube 16 should fit snugly inside tube 19, which should fit snugly inside tube 15. Tubes 15 and 16 with slots 17 and 18 may be extended to create additional intersections of the slots, and tube 19 with slot 20 may be extended, with additional offsets in slot 20, so that all intersections but one are covered.
For ease of construction or for other reasons, any slot in the previous discussion may be replaced by a series of discrete holes, as shown in FIG. 5, wherein tube 21 corresponds to tube 8 of FIG. 2, and holes 22 correspond to slot 7. If the holes are spaced closely together, the function of the apparatus is essentially unchanged. The holes in surfaces 23 and 24, shown in FIG. 6, are spaced closely together, so that during transverse movement of surface 23, either two or three pairs of holes will always intersect and provide openings for the passage of air. The holes in surfaces 25 and 26, shown in FIG. 7, are spaced too far apart; transverse movement of surface 25 can close all openings. Maximum allowable spacing of holes in any specific case will depend upon both hole size and angle of intersection of the two hole series, or of a hole series and a slot.
For ease of definition, it is stated that a fixed surface or a movable surface may contain either an aperture, i.e. the slot, or a series of apertures, i.e. the discrete holes.
Although FIGS. 4 and 5 show tubular surfaces, the application to the surfaces of FIG. 1 is obvious. Also, although the previous discussion has referred to fixed and movable surfaces, it should be obvious that the so-called fixed surfaces may also be movable without altering the essential function of the device. For example, the construction of FIG. 2 could be modified to permit rotation of tube 8, for the purpose of varying the horizontal angle at which air enters the combustion zone, without altering the essential fact that the vertical location at which air enters the combustion zone is controlled by rotation of tube 10 relative to tube 8.
For further ease of definition, it is stated that a surface which is said to be movable is understood to be movable with respect to adjacent surfaces. If a surface is not said to be movable, motion of that surface is not required to produce the desired effect on air flow within the apparatus.
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The location of an air supply in a combustion apparatus is made adjustable by changing the point of intersection of a slot in a movable surface with a slot in a fixed surface. In the preferred embodiment, the fixed and movable surfaces are of tubular construction. Variations include a second movable surface for the purpose of extending the range of adjustment, and the use of discrete holes rather than slots in the fixed and movable surfaces.
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BACKGROUND OF THE INVENTION
In U.S. Pat. No. 5,060,542, there is described an apparatus and method for making and breaking drill pipe joints, and which is a major improvement over prior art. However, the torques generated during making and breaking of the joints are enormous. It would be highly desirable and important to achieve jaws that are more strong, more precision, more rugged, more symmetrical, more easily adjusted, more stable, etc., than are the jaws described in the cited patent.
SUMMARY OF THE INVENTION
It has now been discovered that jaws for the make-and-break apparatus can be made having the desired attributes recited in the preceding paragraph.
In accordance with one aspect of the present invention, a jaw-adjustment nut apparatus is provided that is a segment of a sphere, being adapted to rotate in either direction to any desired setting in order control the size of the gap in the associated jaw. At any one time, when part of the jaw is pivoting for initial gripping or self-energization purposes, only a portion of the sphere is operative--but the remaining portions of the sphere remain available for use during periods when other settings of the jaws have been made.
In accordance with another aspect of the invention, dies are mounted respectively in the hook end and in the head of each jaw, and only one of such dies is rotatable through a large angle about an adjacent portion of the jaw.
In accordance with another aspect of the invention, the relationships are such that the jaws may be moved in both directions in response to rotation of the nut about the spherical segment, there being no necessity to pull on any part of any jaw at any time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing the present apparatus, as mounted on a tool joint;
FIG. 2 shows major portions of the apparatus as viewed from above the top level of jaws, and showing the positions of parts before making of a joint;
FIG. 3 is an isometric view of the jaw shown in FIG. 2;
FIG. 4 is a view, partly and horizontal section, illustrating the components of one set of jaws, the jaws being shown closed on a joint;
FIG. 5 is a vertical sectional view taken on line 5--5 of FIG. 3; and
FIG. 6 is a view generally corresponding to part of the lower portion of FIG. 4 but showing a second embodiment of the tool joint-engaging die construction on the head.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The above cited U.S. Pat. No. 5,060,542 is hereby incorporated by reference herein. Except as specifically stated herein, the construction of the present make-break apparatus, and the method, are substantially the same as that described in the U.S. Pat. No. 5,060,542.
Referring to the drawings, the apparatus comprises a strong welded frame 10 having legs 11 and suspended at the wellhead of an oil well by a three-element suspension means 12.
Mounted in vertically-spaced relationship on frame 10 are three sets of jaws, each in a horizontal plane. The top set of jaws is numbered 21; the middle set 22; and the bottom set 23. The top and bottom jaws 21,23 are identical to each other and are oriented identically to each other in the preferred form--the bottom set being directly below the top one.
The middle set of jaws, number 22, is reverse oriented relative to the top and bottom sets, being adapted to turn the tool joint portion in the opposite direction. The middle set of jaws is in vertical alignment with the top and bottom sets at the regions of the middle set that are adjacent the tool joint.
In the preferred embodiment, top and bottom jaws 21,23 are fixed to frame 10. Conversely, middle jaw set 22 is not fixed to the frame 10, being instead pivotally related to the frame so that the middle jaw set may pivot horizontally relative to the frame. The axis of such pivotal movement is the axis of rotation of jaws 21-23.
The pivotal movement of middle jaw set 22 is effected by a torquing cylinder 24, FIG. 2. Cylinder 24 is strongly pivotally associated with frame 10 by pivot means 25 having a vertical axis.
A second strong vertical-axis pivot means 28 is connected to the middle jaw sets, this being connected to the end of the piston rod (not shown) of torquing cylinder 24. To hold the middle jaw set 22 in its horizontal plane, frame 10 includes upper and lower horizontal frame components 10b,10c which define a horizontal slot 33 as partially shown in FIG. 1. A region of middle set 22 is disposed slidably in slot 33, so that it will remain in a plane parallel to those of the top and bottom jaw sets 21,23.
In the preferred embodiment, all three jaw sets are identical to each other except that--as above indicated-- the center jaw set is reversed relative to the top and bottom sets. Thus, the present description of one jaw set applies also to the other two. For convenience, the top jaw set 21 is the one described.
Top set 21 has a head 36 in which is pivotally mounted a hook 37. Head 36 is fixedly connected to the upper end of the frame. The relationships are such that after the tool joint is initially gripped by the head 36 and by hook 37, rotation of the head 36 in a clockwise direction (all rotation directions being as viewed from above) will cause additional energization (self-energization) of jaws 21 to thereby strongly and effectively grip the tool joint for torquing thereof.
Head 36 has strong thick plate elements 38 and 39 that are horizontally spaced apart so as to form an opening adapted to receive the shank 41 of hook 21 between them. Elements 38 and 39 are strongly secured to each other by top and bottom head plates 42,43 which aid in defining the opening and are held in position by bolts 44.
Element 38 of the head is strongly connected by struts 46 (FIG. 2) to the upper end of the frame.
The shank 41 of hook 37 is flat on the top and bottom sides thereof, the upper and lower surfaces of the shank lying in horizontal planes and close to head plates 42,43. The generally vertical opposite sides of shank 41, at the portion thereof remote from the hook end 47 of hook 37, are portions of the same cylinder and are strongly threaded as indicated at 48. Such cylinder has its axis at the axis of shank 41.
A large diameter, strong nut 50 is threaded onto threads 48. It has four handles H to facilitate turning in either direction. Nut 50 is associated not only with threads 48 but with other portions of a combination pivot and adjustment mechanism described in detail below. The relationships are such that rotation of nut 50 causes the jaws to open or close to the desired position relative to a particular diameter of tool joint. Furthermore, the adjustment mechanism is such that hook 37 pivots about a predetermined vertical axis relative to head 36.
Pivoting of hook 37 relative to head 36 is effected in two ways. Initially, the pivoting is effected by a bite cylinder 52, which is first operated to close the hook 37 on the tool joint so that teeth portions of dies (described below) bite initially on the tool joint. Thereafter, when the head is turned clockwise, hook 37 closes further on the tool joint to powerfully grip it.
The base end of the body of bite cylinder 52 is pivotally connected to a bracket 52b (FIG. 2) on a strut 46. The piston rod of cylinder 52 is pivotally connected to hook element 37 near its hook end 47, at bracket 52c.
The hook end 47 of hook 37 extends forwardly, away from frame 10. The gap or space between the extreme end of hook end 37 and the opposed region of head 36 is open, so that the jaw set 21 may be readily positioned around the tool joint when the entire apparatus is moved toward the tool joint prior to making or breaking thereof.
A typical tool joint is shown, having an upper component 56 threadedly connected to a lower component 57.
In operation, the upper and lower jaw sets 21,23 are alternately closed for torquing of the joint. The middle jaw set 22 is always closed for such torquing. Thus, the middle set cooperates with either the upper set or the lower set to effect torquing.
As above stated, the bottom jaw set is identical to the top one. Also as above stated, the middle jaw set 22 is identical except as indicated above and now further described.
Like upper and lower sets 21,23, the middle set 22 opens away from the frame. Two sets are simultaneously mounted on the tool joint 56,57 when the make-and-break apparatus is moved toward the joint. As above indicated, the middle set is reverse-oriented relative to the top and bottom ones. Thus, the hook end of middle jaw set 22 further energizes and rotates a tool joint component when the middle set is rotated counterclockwise (as viewed from above).
Middle jaw set is pivotally connected (as above indicated) by a pivot means 28 to the end of the piston rod of torquing cylinder 24. Stated more specifically, struts 46 associated with pivot means 28 connect to the head 36 of the middle jaws.
The Combination Pivot and Adjustment Mechanism
Of Each Of The Jaws 21,22 and 23
Referring to FIGS. 3-5, the exterior surface of nut 50 on shank 41 of hook 37 is a surface of revolution about the axis of such nut, which axis is coincident with that of the shank 41. The exterior surface of the working portion (the left portion as viewed in FIGS. 3-5) of nut 50 is a segment 61 of a sphere, that is to say a portion of a sphere defined between parallel planes each of which is perpendicular to the common axis of nut 50 and shank 41. As shown in FIGS. 3-5, such segment of a sphere is near the right side of head 36, which right side is remote from hook end 47.
The diameter of the spherical segment 61 is relatively large, preferably much larger than the distance between the top and bottom surfaces of head 36.
The spherical segment 61 is convex and has a center located at point "C" as shown in FIG. 4. Such point "C" is located in a plane that is midway between parallel planes respectively containing the upper and lower surfaces of shank 41. To keep the center point C in such intermediate plane, and also at the longitudinal axis of shank 41, nut 50 is provided with strong interior threads 62 (FIGS. 4 and 5) that mate with the above-indicated threads 48 on the opposite edges of shank 41. Thus, at any given time, diametrically-opposite portions of threads 62 mate with threads 48 (FIG. 4).
There will next be described the bearing and retainer means associated with nut 50. A strong bearing block 63 is sandwiched between head plates 42,43 as shown in FIGS. 3 and 4, being held very strongly in position by bolts 64. The inner surface 66 of bearing block 63 is spherical (and concave), and is substantially coincident with a portion of the spherical segment 61 when the apparatus is in the assembled condition shown in the drawings.
A second bearing (or retainer) block, numbered 68 in FIGS. 2 and 4, need not be nearly so strong; it is secured by a plate 69 and suitable screws to the plate element 38. Second block 68 has a concave surface that extends surface 61 when the parts are assembled as illustrated. Such concave surface could be spherical but need not be. It is preferably loosely engaged with the sphere 61, and operates as a retainer.
Thus, bearing blocks 63 and 68 and their spherical surface form bearing and retainer means for nut 50, at spherical segment 61. This permits the nut 50 to rotate in two ways, namely about the longitudinal axis of shank 41, and about a vertical axis that is perpendicular to the upper and lower surfaces of shank 41 and that passes through center C. The bearing block 63 and associated bolts are strong because large forces are created between surfaces 61,66 during operation of the apparatus to rotate a section of a drill pipe joint.
Four of the above-indicated handles H are welded to nut 50 in equally spaced relationship about the axis thereof, to permit manual rotation of the nut 50 on shank 41 in either direction, depending upon whether the shank 41 and the entire hook 37 are to be adjusted to the right or to the left as viewed in FIGS. 3 and 4.
It is to be understood that center C is not fixed in position relatively to the shank 41. It is, instead, fixed in position relative to spherical segment 61 which in turn is fixed in position by the bearing blocks 63 and 68 as well as by bearing means described in the following paragraph.
Thrust bearing means, which are also part of the retainer and positioning means for nut 50, are provided on head 36, and comprise bearing surfaces that--regardless of the pivoted position of hook 37 relative to head 36--lie in one of the planes (namely the left planes in FIGS. 3 and 4) defining the spherical segment 61. These are best shown in FIGS. 2, 3 and 5, it being understood that a bearing cover (upper plate) is not shown at the right side of FIG. 2 though it is shown at the left side thereof. The thrust bearing means are on the upper and lower sides of head 36, and are mirror images of each other relative to a horizontal plane containing the longitudinal axis of shank 41.
An arcuate element 71, extending for somewhat more than 180°, is mounted by bolts 72 on a plate 42 or 43. The vertical axis of each arcuate element 72 extends through center C and is perpendicular to the upper and lower surfaces of shank 41. A rotatable bearing 73 is mounted rotatably in each arcuate element 71, such bearing being cylindrical and having a diameter only slightly smaller than the diameter of the inner surface of arcuate element 71.
One side of the rotatable bearing 73 is cut off at a plane that is parallel to the axis of bearing 73 (this being also the axis of arcuate element 71). There is thus formed a bearing surface 74 (FIG. 5) in such plane, which bearing surface is somewhat further from the hook end 47 of hook 37 than are the end edges of arcuate element 71. Thus, the bearing surface may remain in sliding contact with nut 50 even though hook 37 pivots somewhat relative to head 36. The face of nut 50 closest to the hook end 47 of hook element 37 is radial (lying in the above-indicated one plane) and is numbered 76, being in sliding contact with each bearing surface 74 (it being emphasized that there are upper and lower mirror-image bearing assemblies each having a surface 74).
Face 76 is located sufficiently far (FIG. 4) from head 36 to permit pivotal movement of the hook 37 in a horizontal plane through a sufficient angle to open and close the jaws and to permit the jaws to energize. The head opening defined between plates 38,39,42 and 43 is also sufficiently large to permit such pivotal movement.
The bolts 72 extend in each instance through a horizontal cover plate 77, which retains bearing 73 in position but does not interfere with rotation of bearing 73 about the vertical axis through center C.
Operation Of The Apparatus As Thus-Far Described
Let it be assumed that the various cylinders are not pressurized, and that it is desired to change the size of the opening (gap) in each jaw set so that the make-break tool may operate on a different predetermined diameter of tool joint 56,57 in the drill pipe string such as is shown in FIG. 1.
It is then merely necessary to employ handles H in such manner as to spin the three nuts 50 of the three jaw sets 21,22 and 23 to previously determined settings. (In some cases, only two jaws sets are adjusted at a time.) It is to be understood that a scale (or gauge) (not shown) is provided on the shank 41 of each jaw, and these scales have previously-determined markings which when registered with the face of each nut 50 remote from face 76 will indicate to the user that the hook 37 is adjusted to the correct position for a particular diameter of joint.
Because each nut 50 is trapped rotatably between bearings 73,63 and 68, rotation of each nut 50 in either direction will operate through the threads 48,62 to achieve precise movement of shank 41 in either direction to the desired setting. Whether the shank moves to the right or left in FIGS. 3 and 4, for example, makes no difference because either direction of movement is as easily accomplished.
The set-up for the different diameter of tool joint also involves setting (adjusting) stop elements such as are described in the cited U.S. Pat. No. 5,060,542--thereby determining the positions of stop ends 91 shown in FIG. 3 of said patent. These ends are adapted to engage the tool joint in order to achieve correct positioning of the present make-break tool relative to the particular diameter of tool joint.
After the tool is positioned with two of the three jaw openings receiving the tool joint, the appropriate ones of the bite cylinders 52 (FIG. 2) are pressurized so as to move their associated hooks 37 forwardly into clamping relationship with the tool joint. Then, to make or break a joint, torquing cylinder 24 (FIG. 2) is pressurized so as to extend the piston rod (shown in the cited patent) therefrom and thus widely separate the second pivot means 28 (FIG. 2) from cylinder 24. This does two things; it tightens (energizes) each set of jaws so as to increase greatly the gripping force on the associated tool joint section, and it rotates the appropriate tool joint section in the desired direction to make or break the joint. Whether the joint is made or broken depends on which of jaw sets 21,23 is in use (in FIG. 1 the top jaw set is in use and the bottom one is not).
When each set of jaws because thus energized, and when each bite cylinder 52 is operated, each hook 37 pivots about the vertical axis through point C indicated in FIG. 4. Such axis is the center of each bearing 73 and such point C is the center of spherical segment 61.
It is emphasized that when hook 37 rotates in a horizontal plane relative to its associated head 36, only two small portions of spherical segment 61 are utilized. These two portions are those engaged by the spherical faces of bearings 63,68. These small portions lie in the same plane as that of hook 37. On the other hand, during adjustment of the size of the jaw opening in either direction, prior to use of the apparatus to actually make or break a joint, the handles H are rotated so that annular portions of the spherical segment 61 are utilized about (typically) the full circumference of nut 50.
There has thus been described a jaw hook pivoting and jaw hook adjusting mechanism that operates with great precision and great strength. The bearing loads between surfaces 74 and 76, and surfaces 61 and 66, are extremely high during the period when a tool joint is actually being made or broken. The symmetrical nature of the parts, and the size and strength of the elements, result in extremely strong and rugged constructions such as are needed for oil field use.
After the joint has been made or broken, the bite cylinders 52 are operated to retract the hooks 37 away from the drill pipe string, following which the drill pipe string is moved axially to such position that the next joint may be made or broken as desired.
Description Of The Apparatus For Biting, With Precision And Stability, On The Tool Joint
Especially because of the high forces involved, the above-specified precision relative to the axis of each hook 37, the setting of each hook 37, etc., are of great importance. It has further been discovered that by providing certain rotatable and nonrotatable, or small-angle rotatable, die constructions at the opposed faces of the hook end and the head, the strength and stability of the gripping action are much enhanced.
Referring to FIGS. 2-4, this is the first embodiment of die construction.
On the hook end 47 of hook 37, there is a rotatable die segment 81 (FIG. 4) which carries a replaceable, toothed, concave die 82 and which rotates in a bearing 83 in the hook end. End plates 84 are mounted, by screws, on the ends of the die segment 81. There is cooperation between a pin 85 on the hook end, and long arcuate slots in end plates 84, to permit the die segment 81 and thus die 82 to rotate through a large angle about a vertical axis.
Accordingly, and since the described elements 81,82 and 84 rotate relatively freely about the indicated vertical axis, die 82 will self-pivot to a desired angle at which substantial numbers of the vertical die teeth thereof engage the outer side of tool joint section 56 (FIG. 4). For a further description of the die and associated die segment used relative to the hook end of the jaw, reference is made to FIG. 7 of the cited U.S. Pat. No. 5,060,452 (the end plates in such FIG. 7 are larger than those shown herein).
It has now been discovered that, in the present apparatus, the amount of movement of the die on the head 36 should be limited and not free and through a wide angle as is the case relative to the die associated with the hook end 47. In the embodiment of FIG. 4 (and of the other drawings except FIG. 6), the die on head 36 is fixed and does not rotate at all relative to the head. As shown at the center region of the lower portion of FIG. 4, the illustrated die 87 is mounted in a fixed rectangular block 89 which is nonrotatably mounted in a complementary rectangular recess in plate element 39 of head 36. The die 87 is diametrically opposite die 82 when the tool joint section 56 is centered as shown in FIG. 4. Top and bottom plates 89a, and suitable screws, hold elements 87,89 in position.
With the die combination of FIG. 4, there is more stability--than with the die combination described in the cited patent--due to the fact that die 87 does not rotate relative to head 36. It follows that when hook 37 is pivoted counterclockwise (as viewed from above) from the position of FIG. 4, there will be less tendency for the die 87 to shift relative to pipe joint section 56. One result is that the angle through which the pipe joint section is rotated in response to full lengthening of torquing cylinder 24 (FIG. 2) is maximized.
In order to achieve substantially all of the benefits of the embodiment of FIG. 4 but still facilitate precision mounting of the jaws on joint section 56, and also to better spread the load over different teeth of die 87, another embodiment is provided as shown in FIG. 6.
Embodiment of FIG. 6
The embodiment of FIG. 6 is in all respects identical to the embodiment described in all preceding portions of the present application, with the sole exception that the die assembly associated with the head 36 of each jaw set is that of FIG. 6 instead of that of FIG. 4.
In FIG. 6, the die assembly on head 36 is a rotatable die segment 90 that rotates about a vertical axis, as in the case of die segment 81. Segment 90 rotates in a cylindrical recess or bearing portion 39b of plate 39a. Such die segment 90 carries a die 91. Furthermore, there are top and bottom plates 92 that are secured by screws 92a to die segment 90 as in the case of plates 84 associated with the hook end. Screws 92a cooperate with associated arcuate slots 94 and with pin 93 to hold the die segments in the proper positions during periods when the joints are not being made or broken.
Plates 92 are small because the die segment 90 and die 91 pivot only through a small angle about the vertical pivot axis A typical small angle of pivoting is 5°, being vastly less (a small fraction) than the angle through which die segment 81 associated with hook end 47 may pivot.
In the present embodiment, pivoting of the die segment on the head is stopped by brute force--by strong stop means. In the previous embodiment of hook-end die means, and in all die means of the cited patent, pivoting of the die cease by friction and not by action of stop means.
There are wide, thick top and bottom arcuate flanges 90a that seat above and below plate 39a. These flanges are in recesses in top plate 42a and in the unshown bottom plate, there being radial gaps G between these elements radially-outwardly of the flanges 90a.
The slots 94 and associated pins 93 do not at all control the angle through which die segment 90 pivots during mounting on the joint section or during actual torquing. Slots 94 are so long that their ends never contact pin 93. The pivot angle is controlled, instead, by a very strong large-diameter pin 95 that is anchored in a hole in plate element 39a of head 36. This large pin 95 extends upwardly and downwardly, above and below plate 39a, into anchoring grooves in plate 42a and in the unshown bottom plate. It also extends, above and below plate 39a, into top and bottom short recesses (half-slots) 96 in the top and bottom flanges 90a of die segment 90.
In the operation of the embodiment of FIG. 6, the large pin 95, after the jaws are mounted on a tool joint section, is typically spaced away from the end wall 98 of each short recess 96 prior to the time that actual torquing commences. (Stated otherwise, the end wall 98 is spaced from pin 95.) However, a certain amount of pivotal movement of the die segment 90 and die 91 has been permitted, to permit the die 91 to adjust or center itself relative to the tool joint surface (circle) so that a relatively large number of die teeth are engaged and the load is spread, more tangency being achieved. Thus, when torquing commences, the pin 95 is (as above stated) often spaced away from end wall 98 and typically not engaged therewith. The locations of recesses or slots 96 are such that the die segments center, that is to say become tangent, before walls 98 are engaged.
Upon commencement of torquing, that is to say extension of the main cylinder 24 as described above and in the cited patent, the direction of rotation is such that the large pin 95 tends to move toward end wall 98. Thus, the maximum amount that die segment 90 and die 91 may shift relative to pin 95 is (typically) 5°. After the (maximum) about 5° movement, pin 95 engages end wall 98 and the two move together. The die segment 90 no longer can rotate relative to the head plate 39a. There is thus brute-force stopping of rotation of the pin 95 by the wall 98 or (stated otherwise) of wall 98 by the pin 95.
Accordingly, with the construction of FIG. 6, the die 91 can adjust itself and spread the load between teeth, but there is not so much adjustment as to create any substantial tendency to generate instabilities or to permit large lost motion during actual torquing.
The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.
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Apparatus for making and breaking joints in drill pipe strings has three jaws each of which is adjustable to an infinite number of settings. The jaw-adjustment means are symmetrical about a central plane, and incorporate a spherical section. Different portions of the spherical section operate relative to closing and self-energizing of each jaw, the particular operative portion depending upon the exact set or adjusted position of the jaw. Each jaw is constructed for stable clamping of a drill type portion, with only one side of each jaw having a die element that is rotatably mounted. The jaw-adjustment mechanism effects both opening and closing of the jaw, there being no necessity to manually pull on a jaw portion at any time.
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REFERENCE TO RELATED APPLICATION
This application claims the benefit of the priority date of European patent application 04 090 375.9, filed on Sep. 24, 2004, the contents of which is herein incorporated by reference in its entirety.
FIELD OF INVENTION
The invention relates to a method for optimizing the optical power in an optical network that has a plurality of network nodes each having a transmitter and a receiver, and to a corresponding optical network.
BACKGROUND OF THE INVENTION
It is a known practice to transmit data using an optical network. An optical network has a plurality of network nodes which are arranged in accordance with a particular topology, for example a ring topology and a star topology. The individual network nodes each have a transmitter and a receiver. The receiver converts the optical signal emitted by another network node into an electrical signal. An intelligent unit in the network node evaluates the electrical signal and checks, in particular, whether the information contained in the signal is intended for its own network node or is to be forwarded. In the latter case, the electrical signal is converted into an optical signal again by the transmitter and is sent to a further network node.
The serial communications system MOST (Media Oriented System Transport) has become established in recent years for transmitting audio, video, voice and control data using optical waveguides in multimedia networks and, in particular, in the automotive sector. MOST technology has, in the meantime, become the standard for present and future requirements in multimedia networking in motor vehicles. A MOST system provides a bandwidth of up to 24.8 Mbit/s. The network topology in MOST systems is generally a ring topology or a bus topology.
The optical power in an optical network is determined by the optical power levels emitted by the individual optical transmitters of the network nodes. In this case, the optical power is selected in such a manner that, taking into account the path attenuation between a transmitter under consideration and the associated receiver, the optical power detected at the receiver is high enough for reliable signal detection.
SUMMARY OF THE INVENTION
The following presents a simplified summary in order to provide a basic understanding of one or more aspects of the invention. This summary is not an extensive overview of the invention, and is neither intended to identify key or critical elements of the invention, nor to delineate the scope thereof. Rather, the primary purpose of the summary is to present one or more concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
The present invention is directed to a method for optimizing the optical power in an optical network and also for providing a suitable optical network wherein this goal may be achieved.
Accordingly, the present invention comprises initially receiving and detecting the optical power of the optical signal at a network node. Then, it is determined whether the optical power is within or outside a defined range. If the optical power is outside the defined range, a control signal for either increasing or decreasing the optical power is generated for that network node which emitted the optical signal. The control signal is sent to the emitting network node and the latter then increases or decreases the optical power of the emitted optical signal in accordance with the control signal received. The method may be repeated within a regulating operation until the optical power detected at the second network node is within the defined range.
The method of the present invention makes it possible, during operation, to set the optical power emitted by an optical transmitter of a network node to a suitable value as a function of the path attenuation between the transmitter and the associated receiver, thereby optimizing the optical power in the optical network. In this case, the invention ensures, on the one hand, that the signal received by the receiver is large enough to enable reliable signal detection. On the other hand, inefficient operation and an “overload” in the receiver in the case of excessively high optical power levels are prevented.
The optical power that is available to a receiver is dependent on various influencing parameters. Examples of such influencing parameters are, for example, the length and attenuation of the optical fiber through which the light is transmitted, the ambient temperature, ageing processes in the optical fiber and the transmitter, production-dictated discrepancies and any optical coupling that may possibly occur. Despite this variety of parameters which influence the path attenuation between a transmitter and a receiver, the method according to the invention makes it possible to always set that ideal optical power at the transmitter which leads to an optical power level in the receiver that is within a desired ideal range.
In particular, partial failure of the optical system, which may occur when the optical power in the receiver is no longer sufficient for signal detection because of high path attenuation, is also reliably prevented. The possibility of reducing the optical power of the transmitter in the case of low path attenuation also increases the lifetime of the optical transmitter and thus the overall reliability of the component. This is highly advantageous, in particular, in semiconductor lasers, for example in vertically emitting laser diodes (VCSELs).
The optical power of the respective transmitters of the network nodes of the optical network is naturally dependent on the path attenuation of the light transmission path between a respective transmitter and receiver. The optical power levels (which have been set) of the transmitters and the optical power levels detected at the receivers thus reflect the path attenuation between a respective transmitter and receiver. Accordingly, another advantage of the present invention is that the path attenuation on the individual paths of the optical network and changes in the path attenuation may be detected using the optical power levels which have been set and detected and may be used to diagnose the optical network.
The method according to the invention thus also improves the ability to diagnose the optical network, implemented, for example, by storing changes in the attenuation of particular paths in a central memory for retrieval and evaluation using an evaluation system. In another aspect of the invention, it is also possible to define suitable interfaces which can be used to detect the information relating to the respective path attenuations. These improved diagnosis capabilities may be implemented solely on the basis of software, that is to say without additional hardware.
It shall be pointed out that, within the scope of the present invention, the term “optical signal” is a synonym for an optical data signal, that is to say denotes an optical signal that has been modulated in accordance with data to be transmitted. In this case, the data to be transmitted may comprise both control or signaling data and user data.
In one exemplary implementation of the invention, the control signal is transmitted to the first network node via the optical network. The optical network itself thus serves for control signal transmission and feedback to the transmitter of the emitting network node. In principle, however, it is likewise conceivable for the control signals to be sent to the emitting network node via other connections, for example via a local area network and/or the Internet or via a radio link.
In another exemplary implementation, provision is made for signal transmission in the optical network to be subject to a transmission protocol that defines at least one user channel for transmitting user data and at least one control channel for transmitting control and signaling data. In this example, the control signal in the control channel is transmitted to the first network node. The control channel of the optical network thus serves to transmit the control signals.
In particular, provision may be made for the receiver of the second network node to be used to convert the received optical signal into an electrical signal, then, if the optical power detected is outside the defined range, for an electronic module to add the control signal to the electrical signal, and for the electrical signal that has been changed in this manner to be supplied to the transmitter of the second network node and converted into an optical signal. In this case, the electronic module may be arranged in the network node itself or may alternatively be assigned to a network management unit that communicates with the network node electrically.
It shall be pointed out that a control signal is generated irrespective of whether the signals received at the second network node are intended for the second network node or are forwarded to another network node. Thus, respective control signals each relate to the setting of the optical power in a transmission section of the optical network, irrespective of the contents of the transmitted data and their destination.
In one exemplary implementation, the optical power at the second network node is detected by measuring the photodiode current after the optical signal has been converted into an electrical signal. This makes it possible to easily and effectively determine the optical power that has been detected.
The optical network, in one exemplary configuration comprises a serial network in which optical signals are transmitted between adjacent network nodes. In particular, the network has a ring topology and/or a unidirectional network. In principle, however, other network topologies, for example a star topology or a bus topology, may also be implemented. The optical network may also be a bidirectional network.
Further, provision may be made for the control signal generated by the second network node to contain the address of the first network node in the optical network as the destination address. Of course, this is important when the generated control signal passes through a plurality of network nodes on its way to the destination node (e.g., the node that emitted the optical signal).
The destination address, in another exemplary implementation, may be specified without any problems when the transmitter contains its own address as sender information. This is because this sender information can then be given as the destination address. However, this is not always the case. In the case of unidirectional networks, provision may be made for the address of that network node which precedes the second network node in the unidirectional network to be given as the address of the first network node (that is to say as the address of the destination node for the control signal). The network nodes are numbered consecutively and each network node (n, 1≦n≦N) knows that it receives optical signals from a particular preceding network node (n−1).
In still another exemplary implementation, provision is made for the first network node to increase or decrease the optical power by a defined amount after it has received the control signal. The optical power is thus raised or lowered in a stepwise manner until a suitable value exists. Alternatively, the control signal may specify a particular percentage or value by which the optical power is raised or lowered. This would reduce the number of control loops.
In one advantageous embodiment, the optical power levels detected at the individual receivers of the network nodes and/or values derived therefrom (for example attenuation values) are stored in a memory. In this case, the attenuation of the individual transmission paths of the network is determined from the instantaneous optical power levels, for example, on the basis of the data contained in such a memory. The attenuation of the individual transmission paths of the network may be evaluated, for example, as part of a network diagnosis.
The optical network according to the invention has at least one network node having a means for detecting the optical power of an optical signal that was emitted by another network node. The optical network also has a means for determining whether the optical power detected is outside a defined range, and a means for generating, for that network node which emitted the optical signal, a control signal for increasing or decreasing the optical power if the optical power detected is outside the defined range. The optical network further comprises a means for sending the control signal to that network node which emitted the optical signal.
The optical network also has at least one network node having means for increasing or decreasing the optical power of the emitted optical signal as a function of corresponding control signals.
To the accomplishment of the foregoing and related ends, the invention comprises the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail certain illustrative aspects and implementations of the invention. These are indicative, however, of but a few of the various ways in which the principles of the invention may be employed. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail below using an exemplary embodiment with reference to the figures, in which:
FIG. 1 is diagram of an exemplary optical MOST network in which the optical power of the individual transmitters is regulated as a function of the path attenuation between the individual network nodes;
FIG. 2A is a diagram of the frame structure of a data frame that is transmitted in the MOST network of FIG. 1 ;
FIG. 2B is a diagram of a MOST block having 16 data frames as shown in FIG. 2A ;
FIG. 3A is a diagram of the structure of a control message in the control channel of the MOST network; and
FIG. 3B is a diagram of the structure of the message part of a control message of FIG. 2A .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows, as an example of an optical network, a unidirectional network having a ring topology. The exemplary embodiment illustrated in FIG. 1 is a MOST ring 100 . The MOST ring 100 has a plurality of MOST devices 1 - 5 as network nodes. Each MOST device 1 - 5 is a physical unit that has at least one MOST transceiver having a transmitter TX and a receiver RX.
This is illustrated in detail for two MOST devices 2 , and 3 . The MOST device 2 has a transmitter 21 , a receiver 22 and a first electronic module 23 . Another electronic module which is furthermore provided and forms a microcontroller 24 , may likewise be included in the MOST device 2 or alternatively may be located externally. The microcontroller 24 controls the transmitter 21 and, in particular, sets the optical power of the latter. Further, the MOST device 3 and also the additional MOST components 1 , 4 , 5 have corresponding components 31 , 32 , 33 , 34 which are not shown in any more detail for the sake of brevity, in the case of the additional MOST components 1 , 4 , 5 .
At the application level, the individual MOST devices 1 to 5 may have a plurality of components which are referred to as functional blocks representing, for example, a CD player or a telephone. They are known, as such, to persons skilled in the art and are not discussed in any further detail below.
Signals are transmitted in the MOST ring 100 in the following manner. If it is desired, for example, to send a message from the MOST device 2 to the MOST device 5 , this message is first of all sent, by way of the serial structure of the ring, to the device 3 , from the latter to the device 4 and from the device 4 to the device 5 . In this case, the signal intended for the device 5 is transmitted by the transmitter 22 in the form of an optical signal and is passed onto the ring 100 . The emitted signal is detected by the adjacent MOST device 3 , to be precise by its receiver 32 , or converted into an electrical signal. The microcontroller 34 uses signaling information such as the destination address and the message type to check whether the received data are intended for its own node. Since this is not the case in the exemplary embodiment described, the data are passed without any changes, but if appropriate after signal regeneration, to the transmitter 31 and emitted by the latter in the form of an optical signal.
The device 4 performs corresponding optical-electrical-optical conversion. The device 5 then detects that the data which have been sent are intended for the device 5 and the data are taken from the ring. An acknowledgement message is used to inform the device 2 (as the transmitting node) of the receipt so that the latter knows that the emitted data have been reliably received.
To avoid a problem, the optical power received by a receiving node or a receiver 32 should be within a particular range. For example, while the optical power received should be high enough to enable reliable signal detection, it should also not be high enough to avoid an overload. An excessively high optical power in the receiver also reflects an unnecessarily high optical power in the transmitter, which leads to increased power consumption and accelerated ageing of the transmitter. A defined range within which the optical power received by a receiver of a node 1 , 2 , 3 , 4 , and 5 should be, is thus established. Optical power management, which ensures that the received optical power is always in the defined range is described, with reference to exemplary FIG. 1 , wherein an optical signal is sent from the MOST device 2 to the MOST device 3 .
The optical signal emitted by the transmitter 21 of the MOST device 2 (also referred to below as the transmitting node 2 ) is transmitted to the receiver 32 of the MOST device 3 (also referred to below as the receiving node 3 ) via an optical point-to-point transmission path 101 of the MOST ring 100 of FIG. 1 . The receiver 32 comprises, for example, a conventional photodiode. Means which determine the received optical power at the receiver 32 are provided in the receiving node 3 . These means are, for example, integrated in the module 33 that additionally performs preamplification.
The optical power, in one example, is determined by directly measuring the photodiode current of the receiver 32 . In this case, the photodiode current of the receiver 32 is filtered using a low-pass filter, for example. The current that is then present represents a measure of the input optical power and may be converted into a root-mean-square value of the input optical power using a calibration curve.
A check is then, for example, likewise carried out in the module 33 of the receiving node 3 to determine whether the received optical power determined is in the predetermined defined range. If this is not the case, the receiving node 3 forwards the corresponding information to the microcontroller 34 , for example. In this case, the microcontroller 34 may be arranged outside the receiving node 3 or alternatively may also be integrated in the latter. Provision may also be made for the microcontroller 34 , rather than the module 33 , to check whether the optical power received is or is not in the defined range. Furthermore, it is also conceivable, in principle, for the microcontroller 34 to constitute a central microcontroller of the MOST ring 100 rather than being specifically assigned to the receiving node 3 . In the former case, a central unit or a network management unit would thus check whether the optical power received is within the desired defined range.
If the optical power received is not within the desired defined range, the microcontroller 34 or a central network management unit generates, for the transmitting node 2 , a control signal for increasing or decreasing the optical power as a function of whether the optical power received is too low or too high. This control signal is preferably passed onto the control channel of the MOST ring. To this end, the control data of the received optical signal that has been converted into an electrical signal by the receiver 32 are correspondingly overwritten. This is effected, for example, by the microcontroller 34 or additional electronic modules (not illustrated).
A corresponding signal whose control data have been changed is then passed onto the ring 100 in the form of an optical signal by the transmitter 31 and forwarded to the device 4 .
In this case, the control signal that has been generated comprises, as the destination address of the control signal, the address of the device 2 so that the latter may detect that the control signal is intended for the device 2 . Because the serial ring structure is unidirectional, the device 3 may, in this case, simply give the destination address as the device number of the node that is arranged upstream of it in the unidirectional MOST ring 100 . If, for example, the individual MOST devices have the addresses 1 , 2 , . . . n, . . . N, the respective receiving node gives the address n−1 as the destination address.
The control signal is passed to the device 4 , from the latter on to the device 5 , from the latter on to the device 1 and from the device 1 to the device 2 . The device 2 uses the destination address to detect that the corresponding control signal is intended for the device 2 . It evaluates the control signal to determine whether an increase or a decrease in the optical power is required. The optical power is then increased or decreased accordingly.
The power that has been correspondingly changed is again detected by the receiving node 3 , and if the optical power received is still not within the desired defined range, it is changed by emitting a further control signal. The optical output power of the transmitting node 2 is accordingly regulated until the optical power received at the receiving node 3 is within the desired range.
Corresponding regulating operations, for example, also take place between the further MOST devices of the ring, that is to say between the MOST device 3 and the MOST device 4 , between the MOST device 4 and the MOST device 5 etc. An ideal optical power level may thus be provided on each transmission path of the MOST ring 100 .
The generation of an exemplary control signal in the control channel of the MOST ring 100 is explained, by way of addition, with reference to exemplary FIGS. 2A , 2 B, 3 A, 3 B. FIG. 2B shows a MOST block having a length of 1024 bytes and containing sixteen frames 6 each having a length of 128 bytes. FIG. 2A shows such a MOST frame 6 . The frame 6 has a first region 61 having a length of 1 byte and containing management or administrative information. A second region 62 having a length of 60 bytes contains synchronous data for multimedia applications, for instance audio or video data. A third region 63 contains asynchronous data, for example packetized IP data for time-insensitive applications. A fourth region 64 comprises a length of 2 bytes containing control data. A fifth region has a length of 1 byte that contains CRC and parity information.
Since each frame contains 2 bytes of control data, a MOST block contains a total of 16×2=32 bytes of control data which may be regarded as block 8 below FIG. 2B . The 32 bytes of control data transmit data associated with the control channel of the MOST ring.
FIG. 3A shows an exemplary corresponding control data frame 8 having a length of 32 bytes. A first region 81 having a length of 1 byte contains administrative information. A second region 82 having a length of 2 bytes contains the destination address. A third region 83 having a length of 2 bytes contains the source address. A fourth region 84 having a length of 2 bytes contains the message type. A fifth region (message block) 85 having a length of 24 bytes contains the actual control messages. A sixth region 86 having a length of one byte contains the CRC checksum. A seventh region 87 having a length of 1 byte contains administrative information.
FIG. 3B shows, by way of example, the subdivision of the message block 85 of FIG. 3A . Various regions 851 - 857 which define particular functions and parameters are again defined. In the context of the present invention, the control signal relating to an increase or decrease in the optical power of an optical transmitter, in one example, is written to the message block 85 . The address “n−1” is given as the destination address in the second region 82 .
The configuration of the invention is not restricted to the exemplary embodiment described. Rather, numerous alternative configurations are conceivable. By way of example, the invention may also be implemented in other topologies, for example a bus structure or a star structure. This is possible without problems since the setting of the optical power is accommodated between two adjacent network nodes, independent of the role of the network topology. A bidirectional network may also be used instead of a unidirectional network. One exemplary application of the solution according to the invention is in the automotive sector, in the field of local area networks and in home networking.
While the invention has been illustrated and described with respect to one or more implementations, alterations and/or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In particular regard to the various functions performed by the above described components or structures (assemblies, devices, circuits, systems, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component or structure which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary implementations of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Furthermore, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in either the detailed description and the claims, such terms are intended to be inclusive in a manner similar to the term “comprising”.
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The invention relates to a method for optimizing the optical power in an optical network that has a plurality of network nodes each having a transmitter and a receiver. The method comprising generating an optical signal at a first network node, receiving the optical signal at a second network node, detecting the optical power of the optical signal at the second network node, determining whether the optical power detected is outside a defined range, and in this case, generating, for the first network node, a control signal for increasing or decreasing the optical power, sending the control signal to the first network node, and increasing or decreasing the optical power of the optical signal emitted at the first network node. The invention further relates to an optical network having network nodes which are operable to implement this method.
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REFERENCE TO CROSS-RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/045,436 filed Nov. 7, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of online surveys. More particularly, but not by way of limitation, the present invention relates to the field of reusable software components for conducting surveys over a distributed computing network.
BACKGROUND OF THE INVENTION
[0003] In order to effectively market products and services to consumers both on and off the World Wide Web (the “Web” or “WWW”), it is necessary to collect accurate and relevant information regarding consumers and their purchasing habits. One way that Web sites have traditionally collected information is through the use of Web survey applications. Web survey applications conduct online surveys by providing a user with an input form that includes a number of questions along with input fields in which to provide answers to the questions. The user may then answer the survey by typing an answer for each question into the input fields. When the user has completed the survey, the user may transmit the provided answers back to the Web survey application. The survey answers may then be utilized, along with other user's answers to the survey, to better market the concerned product or service.
[0004] While Web survey applications are able to gather a great deal of information from a user, they are not without their drawbacks. The main drawback associated with Web survey applications stems from the fact that the lifetime of the Web survey application and the survey questions themselves are frequently different. For instance, a marketing group may provide a Web site that includes a survey for a particular type of product. The survey may include questions on customer satisfaction with the particular product and may be utilized for 90 days. After the survey is completed, the marketing group may wish to change the survey questions to focus on another type of product for a different time period. Changing the survey questions, however, can be very time consuming and expensive.
[0005] With prior art Web survey applications it is very difficult to change the application to provide a new set of survey questions. In particular, changing survey questions typically requires writing new application code to support the new questions, testing the new application code, and then deploying the new application code. This process be time consuming and expensive. What is needed, therefore, in light of these problems, is a Web survey engine that is reusable and that does not require program code to be modified in order to implement a new Web survey.
SUMMARY OF THE INVENTION
[0006] The present invention solves the above-described problems by providing a method, computer system, and computer-readable medium for conducting an online survey that advantageously does not require the modification of program code in order to implement a new survey.
[0007] Generally described, the present invention comprises a computer system for conducting an online survey including one or more questions. A survey database maintains the survey questions and data identifying the type of input field that should be provided for responding to each question. When a request is received for a network resource, such as a Web page, referencing the online survey, the contents of the survey database are utilized to generate displayable content for conducting the online survey. The survey questions are maintained in the survey database separately from the application code for displaying the survey questions. Therefore, only the questions in the survey database need to be modified to provide a new survey. The application code for generating the survey is generic to all surveys and does not need to be modified.
[0008] More specifically described, the present invention provides a computer system for generating an online survey. The computer system comprises a survey database that contains questions to be utilized in the survey and data identifying the type of input field corresponding to each question. The survey database also includes data that describes how each input field should be displayed. The survey database may also include data identifying the ordering sequence of the questions and data indicating whether particular questions should be included or excluded from a given survey. The survey database may also include data identifying a corresponding application, form name, and version number.
[0009] The computer system provided herein also comprises a network resource for generating the content necessary to conduct the survey and a software component for receiving and responding to requests for the network resource. When a request for the network resource is received, the software component compiles an executable class file capable of generating the content necessary to display the questions and input fields in a Web browser. The survey database, including the questions, input field types, and sequence information, is utilized to generate the class file. The software component then executes the class file and returns the resulting content as a response to the request for the network resource. In this manner, the online survey questions may be displayed in a Web browser with corresponding input fields. When the input fields have been populated with response data, the response data may be submitted to the software component for storage in a response table.
[0010] According to one actual embodiment of the present invention, the software component may determine whether a previously compiled version of the class file should be utilized to respond to the request for the network resource. If the request for the network resource is a first request for the network resource, a previously compiled version of the class file will not be utilized. Additionally, if the software component was reset since the previous access of the network resource was accessed, the previously compiled class file will not be utilized. Otherwise, the previously compiled class file will be utilized, thereby providing a faster response to the request for the network resource.
[0011] The present invention also provides an apparatus and computer-readable medium for providing a reusable online survey engine. Additional details regarding the present invention will be provided in the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a network architecture diagram showing an illustrative operating environment for an actual embodiment of the present invention;
[0013] FIG. 2 is a block diagram showing an illustrative hardware architecture for a Web server computer utilized in an actual embodiment of the present invention;
[0014] FIG. 3 is a block diagram showing the format and contents of an illustrative survey database utilized in an actual embodiment of the present invention;
[0015] FIG. 4 is a screen diagram illustrating a web browser screen display including an illustrative web survey produced by an actual embodiment of the present invention;
[0016] FIG. 5 is a block diagram showing the format and contents of an illustrative response table utilized in an actual embodiment of the present invention;
[0017] FIG. 6 is a flow diagram showing an illustrative routine for processing a request for a network resource that includes an electronic survey according to an actual embodiment of the present invention;
[0018] FIG. 7 is a flow diagram showing an illustrative routine for compiling a network resource that includes an electronic survey according to an actual embodiment of the present invention; and
[0019] FIG. 8 is a flow diagram showing an illustrative routine for processing a request to submit the results of a completed survey form according to an actual embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] The present invention is directed to a method, computer system, and computer-readable medium for providing a reusable online survey engine. Aspects of the present invention may be embodied in an executable software component for providing the functionality described herein. Additionally, aspects of the present invention may be embodied in software components utilized in conjunction with a Web server application program, such as the IPLANET WEB SERVER, provided by IPLANET E-COMMERCE SOLUTIONS—A SUN|NETSCAPE ALLIANCE, of Palo Alto, Calif.
[0021] Referring now to the figures, in which like numerals represent like elements, an actual embodiment of the present invention will be described. Although aspects of the invention will be described in the general context of an application program that executes on an operating system in conjunction with a server computer, those skilled in the art will recognize that the invention also may be implemented in combination with other program modules. Generally, program modules include routines, programs, components, data structures, and the like, that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the invention may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, and the like. Although the invention is also described as being practiced in distributed computing environment, where tasks are performed by remote processing devices that are linked through a communications network, other possible implementations should be apparent to those skilled in the art.
[0022] Referring now to FIG. 1 , an illustrative operating environment for an embodiment of the present invention will be described. Aspects of the present invention are implemented as an executable software component executing on a server computer, such as Web server computers 6 A- 6 N, accessible via a distributed computing network, such as the Internet 4 . As is well known to those skilled in the art, the Internet 4 comprises a collection of networks and routers that use the Transmission Control Protocol/Internet Protocol (“TCP/IP”) to communicate with one another. The Internet typically includes a plurality of local area networks (“LANs”) and wide area networks (“WANs”) that are interconnected by routers. Routers are special purpose computers used to interface one LAN or WAN to another. Communication links within the LANs may be twisted wire pair, or coaxial cable, while communication links between networks may utilize 56 Kbps analog telephone lines, 1 Mbps digital T-1 lines, 45 Mbps T-3 lines or other communications links known to those skilled in the art. Furthermore, computers, such as client computer 2 , and other related electronic devices can be remotely connected to either the LANs or the WANs via a permanent network connection or via a modem and temporary telephone link. It will be appreciated that the Internet 4 comprises a vast number of such interconnected networks, computers, and routers.
[0023] A client computer 2 capable of executing a Web browser application program (not shown), such as Microsoft® Internet Explorer, may be utilized to transmit a request for a Web page or other type of network resource to one of the Web server computers 6 A- 6 N. As is well known to those skilled in the art, the Web is a vast collection of interconnected network resources, including “hypertext” documents written in Hypertext Markup Language (“HTML”), or other markup languages, that are available from “Web sites” accessible through the Internet 4 . A Web site is provided by a Web server computer, like Web server computers 6 A- 6 N, connected to the Internet 4 , that has mass storage facilities for storing such network resources, and that executes administrative software for handling requests for the network resources.
[0024] Large-scale Web sites are typically implemented utilizing a two-tier computer systems architecture as shown in FIG. 1 . The first tier typically comprises one or more “front-end” Web server computers, like Web server computers 6 A- 6 N, that receive and process live requests for network resources from client computers 2 connected to the Internet 4 . As is well known to those skilled in the art, the first tier Web servers are frequently connected to the Internet 4 through a load balancing device 5 , such as the Local Director™ from Cisco Systems®. The load balancing device 5 intercepts requests intended for one of the Web server computers 6 A- 6 N, and forwards each request to a Web server computer that has computing resources available to respond to the request. In addition to the Web server computers 6 A- 6 N, a large-scale Web site may also include a “back-end” server computer (not shown) that stores network resources that may be served to client computer 2 by one of the Web server computers 6 A- 6 N. Additional details regarding the operation of the Web server computers 6 A- 6 N will be provided below with respect to FIGS. 2-8 .
[0025] Referring now to FIG. 2 , a hardware architecture for an illustrative Web server computer 6 will be described. The Web server computer 6 comprises a general purpose server computer for receiving and responding to Hypertext Transfer Protocol (“HTTP”) requests as known to those skilled in the art. The Web server computer 6 comprises a conventional server computer, including a central processing unit 8 , a system memory 12 , and a system bus 10 that couples the system memory 12 to the processing unit 8 . The Web server computer 6 also typically includes at least some form of computer-readable media.
[0026] Computer-readable media can be any available media that can be accessed by the Web server computer 6 . By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, random access memory (“RAM”), read only memory (“ROM”), EPROM, EEPROM, flash memory or other solid-state memory technology, CD-ROM, digital versatile disks (“DVD”) or other optical 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 the Web server computer 6 .
[0027] According to an embodiment of the present invention, the system memory 12 includes a ROM 16 and a RAM 14 . A basic input/output system (“BIOS”) (not shown), containing the basic routines that help to transfer information between elements within the Web server computer 6 , such as during start-up, is stored in the ROM 16 . The Web server computer 6 further includes a mass storage device 22 , such as a hard disk drive, a magnetic disk drive, e.g., to read from or write to a removable disk, or an optical disk drive, e.g., for reading a CD-ROM disk or to read from or write to other optical media such as a DVD. The Web server computer 6 may include a combination of such mass storage devices. The mass storage device 22 is connected to the system bus 10 through a mass storage device interface (not shown).
[0028] As described above with respect to FIG. 1 , the Web server computer 6 operates in a networked environment. According to an embodiment of the invention, the Web server computer 6 communicates with the client computer 2 over the Internet 4 . The Web server computer 6 connects to the Internet 4 through a network interface unit 18 . It should be appreciated that the network connections shown are illustrative and other means of establishing a communications link between the Web server computer 6 and the Internet 4 may be utilized.
[0029] A user may control the operation of the Web server computer 6 through traditional input devices such as a keyboard or a mouse. These and other input devices may be connected to the central processing unit 8 through an input/output controller 20 that is coupled to the system bus 10 . A monitor (not shown) or other type of display device may also be connected to the system bus 10 via a video display interface (not shown). Additionally, the Web server computer 6 may include other peripheral output devices, such as a printer.
[0030] A number of program modules may be stored in the mass storage device 22 and RAM 14 , including an operating system 24 suitable for controlling the operation of a server computer, such as the SOLARIS operating system from SUN MICROSYSTEMS of Palo Alto, Calif. Additionally, a Web server application program 26 may be stored in the mass storage device 22 and the RAM 30 , such as the IPLANET WEB SERVER, provided by IPLANET E-COMMERCE SOLUTIONS—A SUN|NETSCAPE ALLIANCE, of Palo Alto, Calif. As known to those skilled in the art, the Web server application program 26 is operative to receive HTTP requests through the network interface 18 and to respond to those requests. Typically, an HTTP request will take the form of a request for a network resource such as a JAVA server page (“JSP”) page, a page encoded in HTML, a graphics file, or another application program stored at, or accessible to, the Web server computer 6 .
[0031] In conjunction with the Web server application 26 , the Web server computer 6 may also maintain a JAVA runtime extension package 28 that supports the use of JAVA servlets and JSP pages on the Web server computer 6 . The JAVA runtime extension package 28 comprises a JAVA virtual machine 30 which includes a servlet engine 32 and a JSP engine 34 . As known to those skilled in the art, JAVA servlets are programs written in the JAVA programming language from SUN MICROSYSTEMS that execute on a server computer as opposed to a client computer. The JAVA virtual machine 30 interprets JAVA programs that have been compiled into byte-code and stored in a class file.
[0032] JSP pages provide a simplified way to create Web pages that display dynamically-generated content. JSP pages utilize extensible markup language (“XML”) tags and scriptlets written in JAVA to encapsulate the logic that generates the content for the page. JSP passes any formatting tags directly back to the response page. In this way, JSP pages separate the page logic from its design and display. More specifically, JSP pages are created to include JSP technology-specific tags, declarations, and possibly scriptlets, in combination with other static (HTML or XML) tags. The JSP engine 34 interprets the tags and scriptlets contained in a JSP page and generates a class file which, when interpreted by the servlet engine 32 , generates and returns the desired content. A JSP page may include calls to JAVA code 36 , JAVABEANS components, the JAVA Database Connectivity (“JDBC”) application programming interface, or other types of components. A JSP page may also include a file. A JSP page has the extension “.jsp,” which signals to the Web server application 26 that the JSP engine 34 will process elements on the page.
[0033] The Web server computer 6 also maintains a survey JSP page 42 on the mass storage device 22 . Using the above-described process for executing JSP, the survey JSP page 42 generates the content for an online survey. As will be described in greater detail below with respect to FIGS. 6-8 , the survey JSP page 42 utilizes a survey database 38 to generate content for displaying the survey questions and input fields. The survey JSP page 42 also utilizes a response table 40 to save responses to the online survey. Additional details regarding the format and structure of the survey database 38 and the response table 40 are described below with reference to FIGS. 3 and 5 , respectively.
[0034] Those skilled in the art should appreciate that although the present invention is described herein as being implemented using JSP pages, other technologies for dynamically generating content may be utilized to implement the present invention. For instance, Active Server Pages (“ASP”) from MICROSOFT CORPORATION of Redmond, Wash., could be utilized to implement the present invention. Those skilled in the art should also appreciate that although the present invention is described in the context of a Web server application, an application server may also be utilized to provide the functionality described herein.
[0035] Turning now to FIG. 3 , the format and contents of the survey database 38 will be described. As discussed briefly above, the survey database 38 is utilized by the survey JSP page 42 to generate the content necessary for conducting an online survey. The survey database 38 defines the content of the online survey and describes how the content should be displayed. In particular, the survey database 38 contains a question field 44 D that contains the questions that may be utilized in the online survey. For each question present in the question field 44 D, an entry is also provided in a response type field 44 F and a response parameters field 44 G. The response type field 44 E comprises data indicating what type of input field should be generated for each question. For instance, the response type field 44 E may indicate that a text field for entering numbers, words, or other small pieces of text, a text area field for free-form, multi-line text entries, a radio button for picking one item in a list, or other type of input field should be displayed. The response parameters field 44 G includes data indicating how the input field corresponding to each question should be displayed. For instance, an entry in the response parameters field 44 G corresponding to a text field may indicate that a specified number of characters be provided in the text field. Similarly, an entry in the response parameters field 44 G corresponding to a text area input field may indicate that a specified number or rows and columns be displayed for text entry. Likewise, an entry in the response parameters field 44 G corresponding to a radio button may provide the response corresponding to the button, such as “yes” or “no.” Other response fields and response parameters known to those skilled in the art may be utilized in addition to those described here and shown in FIG. 3 .
[0036] The survey database 38 may also include an “active?” field 44 n that indicates whether or not a particular question should be included in the survey. The survey database 38 may also include a sequence field 44 e that indicates the ordering sequence for the questions. The survey database 38 may further include an application name field 44 A identifying a software application associated with the questions, a form name field 44 B identifying a particular Web form associated with the question, and a version field 44 C identifying a version for the survey. Through the use of these fields, only questions associated with a particular application, form, or version may be selected for use with a particular online survey.
[0037] Referring now to FIG. 4 , an illustrative screen display showing a Web page generated by a software component provided in actual embodiment of the present invention will be described. FIG. 4 shows a Web browser window 46 displaying a Web page generated by the present invention based upon the illustrative contents of the survey database 38 shown in FIG. 3 . In particular, the Web browser window 46 includes questions 48 A- 48 N corresponding to the questions stored in the question field 44 D. Likewise, the Web browser window 46 has response fields 50 A- 50 N generated based upon the contents of the response type field 44 F and the response parameters field 44 G for each question. For instance, the response field 50 A is eight characters wide, the response field 50 B is ten characters wide, and the response field 50 is 80 characters wide and three rows high. Additionally, the questions 48 A- 48 N are presented in the order specified by the sequence field 44 E and only those questions identified as displayable in the “active?” field 44 N are displayed. An illustrative routine for generating the content necessary to create the contents of the Web browser window 46 will be described below with reference to FIGS. 6 and 7 .
[0038] Referring now to FIG. 5 , an illustrative response table 40 will be described. As mentioned briefly above, the response table 40 is utilized to store the responses provided as answers to the survey questions. The response table 40 includes an application name field 50 A that identifies the survey application with which the questions are associated. Similarly, the response table 40 includes a form name 50 B that identifies a particular Web form associated with the survey and a version field 50 C that identifies the version number of the survey. The survey table 40 also includes a question field 50 D that stores a question and a response field 50 N that stores the response 52 associated with the question. In this manner, the responses provided by one or more users to a survey may be stored in a single table, or database, and sorted or analyzed together.
[0039] Referring now to FIG. 6 , an illustrative Routine 600 will be described for processing a request for a network resource that includes an electronic survey. As described briefly above, the survey JSP page 42 contains program code necessary to generate the content for displaying the online survey from the contents of the survey database 38 . The Routine 600 begins a block 600 where a request for the survey JSP page 42 is received at the Web server computer 6 from a Web browser application executing on a client computer 2 . The Routine 600 then continues from block 602 to block 604 , where a determination is made as to whether a previously compiled class file should be utilized to respond to the request for the survey JSP page 42 . As mentioned above, a JSP page is compiled into an executable class file by the JSP engine 34 . The class file may then be interpreted by the JAVA virtual machine 30 and its output returned in response to the request for the JSP page.
[0040] A previously compiled class file would therefore not be available if the request for the survey JSP page 42 is the first such request. Additionally, a previously compiled class file will not be utilized if the Web server application 26 has been reset since the previous request for the survey JSP page 42 . Accordingly, if the request for the survey JSP page 42 is the first such request or if the Web server application 26 has been reset since the last access of the survey JSP page 42 , the Routine 600 continues to block 608 . If these conditions are not met, the Routine 600 branches to block 606 , where the previously compiled class file associated with the survey JSP page 42 is retrieved. The Routine 600 then continues from block 606 to block 610 .
[0041] At block 608 , the survey JSP page 42 is compiled into a class file that may be interpreted by the JAVA virtual machine 30 to respond to the request for the survey JSP page 42 . An illustrative Routine 700 is described below for compiling the survey JSP page 42 into byte-code compatible with the JAVA virtual machine 30 . From blocks 608 and block 606 , the Routine 600 continues to block 610 where either the previously compiled class file or the recently compiled class file are executed by the JAVA virtual machine 30 . Markup language content capable of being displayed in a Web browser is generated when the class file is executed. This content generates the questions and input fields as specified in the survey database 38 .
[0042] At block 612 , the content generated by the execution of the class file, including the survey questions and response fields, is transmitted in response to the request for the survey JSP page 42 . This content may then be displayed in a Web browser. The response fields may be completed by a user and the response data transmitted back to the Web server application 26 . An illustrative Routine 800 for receiving and processing the response data is described below with reference to FIG. 8 . The Routine 600 continues from block 612 to block 614 , where it ends.
[0043] Turning now to FIG. 7 , an illustrative Routine 700 will be described for compiling the survey JSP page 42 into byte-code compatible with the JAVA virtual machine 30 . The Routine 700 begins at block 702 , where code is generated for any static markup language found within the survey JSP page 42 . Generally, this process involves simply passing the static HTML or XML directly through to the compiled code. From block 700 the Routine 700 transitions to block 704 , where the first question for the identified survey is retrieved from the survey database 38 . The Routine 700 then continues to block 706 , where a determination is made as to whether the question is active and should be included in the survey. The “active?” field 44 N for the current question is consulted to make this determination. If the current question should not be included in the survey, the Routine 700 branches to block 712 .
[0044] If, at block 706 , it is determined that the current question should be included in the survey, the Routine 700 continues to block 708 . At block 708 , code is generated for displaying the question and the associated response field. In order to generate this code, the question field 44 D, response type field 44 F, and response parameter field 44 G associated with the question may be utilized. Once the code has been generated for the current question and response field, the Routine 700 continues to block 710 , where a determination is made as to whether more questions are contained in the survey database 38 for the identified survey. If additional questions remain, the Routine 700 branches to block 712 , where the next question is retrieved, and to block 710 where code for the question is generated. If no additional questions remain, the Routine 700 continues to block 714 .
[0045] At block 714 , code for generating the questions and response fields may be reordered so that the questions and response fields are generated in a sequence as specified by the sequence field 44 E of the survey database 38 . The Routine 700 then continues to block 716 , where the completed JAVA class file is saved. When executed by the JAVA virtual machine 30 , the class file will generate the markup language code necessary to display the questions and response fields in a Web browser. From block 716 , the Routine 700 continues to block 718 , where it returns to block 610 , described above with respect to FIG. 6 . The processing illustrated at blocks 704 , 706 , 708 , 710 , and 712 may be performed by making a call to an external database.
[0046] Referring now to FIG. 8 , an illustrative Routine 800 will be described for processing a request to submit the results of a completed survey form according to one actual embodiment of the present invention. When a user has completed the survey by providing answers to each of the survey questions in the response fields, the user may select a “submit” button to submit the results of the survey to the Web server application 26 . The Routine 800 begins at block 802 , where such a request to submit the response data is received. The submit request will include data identifying the questions, the response data corresponding to each question and response field, and the application name, form name, and version number for the survey. Once this information has been received, the Routine 800 will continue to block 804 , where the survey response data will be stored in the response table 40 . The Routine 800 then continues to block 806 , where it ends.
[0047] Based upon the foregoing, it should be appreciated that the present invention provides a method, computer system, and computer-readable medium for conducting an online survey. Moreover, the above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A computer system, method, and computer-readable medium for conducting an online survey including one or more questions are provided. A survey database contains the survey questions and data identifying the type of input field that should be provided for responding to each question. When a request is received for a network resource referencing the online survey, the contents of the survey database are utilized to generate the online survey. The survey questions are maintained in the survey database separately from the application code for displaying the survey questions. Only the questions in the survey database need to be modified to provide a new survey. The application code for generating the survey is generic to all surveys and does not need to be modified.
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This nonprovisional application claims priority under 35 U.S.C. §119(a) to German Patent Application No. 10 2008 005 941.2, which was filed in Germany on Jan. 24, 2008, and which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a device for comminuting feedstock.
2. Description of the Background Art
The comminuting of feedstock is a central component of mechanical process engineering in which a starting material is divided by separation into smaller parts. In this case, the feedstock is altered in its size, form, or composition in view of its later use. Separation methods suitable for this provide for comminuting by means of tearing, beating, rubbing, grinding, or cutting. An example is the preparation of waste products, in which size reduction of the feed material is a requirement for processing in subsequent processing stations or in which separation into various components, present in the feedstock, occurs simultaneously during comminuting.
It is known for comminuting by means of cutting to move the cutting edges of cutting tools past one another to execute an effective motion. Apart from the type of feedstock and its insertion during the cutting process, the cutting geometry determined by the machine structure as well is a major determining factor for the cutting process. To achieve a clean cut, it is necessary in particular that the active cutting edges of the cutting tools slide past one another while maintaining an optimal blade clearance, which depends on the type of feedstock. With an increase in the distance between the jointly acting cutting edges, the effectiveness of the cutting process declines, because part of the energy to be applied for grinding, tearing, or crushing the feedstock is used up. As a result, increased mechanical stress arises, which accelerates signs of wear, reduces operating reliability, and not least increases energy consumption. Maintaining an optimal cutting geometry is very important therefore.
U.S. Pat. No. 4,684,071 discloses a device for comminuting used tires, in which a vehicle tire is divided by counter-rotating cutting rotors. The cutting rotors including cutting discs which are arranged on a shaft at an axial distance and are populated at their circumference with cutting tools, whereby the cutting discs of the one rotor engage with a smaller radial overcutting into the gaps of the other cutting rotor. Because the cutting tools are exposed to great mechanical stress during operation and have a correspondingly great wear, the cutting tools are affixed detachably to the cutting discs, so that they can be replaced by new or resharpened tools.
Two possible ways of affixing the cutting tools to the cutting discs are disclosed in U.S. Pat. No. 5,730,375. It is possible, on the one hand, to form the circumferential surface of each cutting disc in the shape of a polygon, which results in a planar support surface for the cutting tools. The cutting tools are bolted down by means of radially acting bolts, which are accessible from the top side of the cutting tools and extend into the circumferential area of the cutting discs, whereby the heads of the bolts come to lie within corresponding recesses. Because during damage to cutting tools due to rough comminuting operation the support surface for the cutting tools and the tapped holes in the cutting discs become damaged and must be repaired when the cutting tools are changed, another embodiment, depicted in U.S. Pat. No. 5,730,375, comprises affixing the cutting tools with the interconnection of a bearing plate on the outer circumference of the cutting discs. This has the advantage that in the case of damage only the bearing plates need to be replaced but the entire support surface of the cutting discs need not be resharpened. In addition, to take up the fixing bolts bushings are provided, which have both an inside and outside thread and are screwed into radial holes in the disc rotor. With their inside threads, the bushings in turn take up the fixing bolts. If an inside thread is damaged, the threaded bushing can be replaced as a whole unit without having to work on the disc rotor itself.
During operation of comminuting devices of this type, large axial forces arise, which are passed via the cutting tools to the cutting discs. These forces must be absorbed by the fixing bolts, which are stressed thereby by shearing and bending. Because the load bearing capacity of each bolt is limited, the removal of the total load requires a relatively large number of fixing bolts, which, when the cutting tool is changed, entail a correspondingly large amount of work because of their loosening and retightening.
Another factor is that the positioning of the cutting tools on the cutting discs is carried out with the fixing bolts. As a result of the play between the cutting tool and the fixing bolt, large tolerances arise during the setting of the blade clearance, which are an obstacle to maintaining a precise cutting geometry and entail the previously described negative effects on the cutting process.
Another factor is that based on geometric circumstances and static requirements, the fixing bolts may be disposed only with maintenance of a minimum distance to the transverse edge of the cutting tools. The arising leverages with a nonuniform load application during the comminuting process lead to a nonoptimal load removal, which must be considered in dimensioning the fixing bolts.
To find a remedy here at least in part, European Pat. No. EP 1 289 663 A1, which corresponds to U.S. Publication No. 20030122006, and which discloses a rotor for a generic comminuting device, in which the cutting tools are affixed laterally to a tool holder by means of screws, optionally with the interconnection of compensating plates. The thus arising cutting unit comprising tool holder and cutting tools is affixed by radially acting screws at the outer circumference of a cutting blade, whereby positioning pins are provided for exact positioning of the cutting unit. As a result, the positioning accuracy of the tool holder relative to the cutting disc is in fact improved, but dimensional inaccuracies are again introduced into the system by the screwing of the cutting tools to the tool holder, optionally with inserted distance plates; these in turn undo this advantage.
In view of the static load removal behavior, in this type of construction, axial stress is introduced via the fixing screws and the positioning pins into the cutting discs with a load removal cross section limited by the number and diameters of the screws or pins. In addition, here as well no optimal force transfer from the cutting tool to the cutting disc is possible, because the positioning pins due to construction must also maintain a minimum distance to the transverse edges of the tool holder.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a device in which the cutting process is carried out with the greatest precision possible with simultaneous improvement of the load introduction into the cutting discs and with minimizing of the effort for changing the cutting tools.
A principle of the invention is the separation of the functional units for secure and positionally accurate fixation of the cutting tools on the cutting discs. In this case, a splitting of functions occurs, on the one hand, in the clamping down and securing of the cutting tools on the cutting disc, and, on the other, in the securing of the snug fit of the cutting tools in the predefined desired position on the cutting disc.
The clamping down of the cutting tool according to the invention is carried out with radially acting bolts. Experience has shown that bolts are not up to the rough comminuting operation within generic devices and are therefore frequently bent or otherwise damaged, so that loosening of bolts and thereby replacement of the comminuting tools are possible only with great effort, and the bolts usually need to be replaced by new ones.
Because in a device according to an embodiment of the invention the fixing bolts are only stressed during pulling and are therefore free of transverse force and momentum stresses, their axial load-bearing behavior can be fully utilized.
The other functional units to secure the snug fit of the cutting tool are used primarily to secure the position of the cutting tool in the axial direction to assure the optimal cutting clearance and thereby the optimal cutting geometry. By placing a positive fit groove on one side and a positive fit strip on the other side, in comparison with known devices, relatively large areas for absorbing the load arise, which also permit the introduction of large forces securely into the rotor without damage to the comminuting tools.
For the advantageous case that the positive fit groove and the positive fit strip extend over the entire length of the bottom side of the cutting tool, very favorable starting geometric conditions arise to keep a secure position also with a nonuniform load application.
According to an embodiment of the invention, the positive fit groove has a cross section that narrows trapezoidally toward the bottom of the positive fit groove. This facilitates, on the one hand, the setting of the cutting tool on the cutting disc. On the other hand, loosening of the cutting tool is promoted by this, because jamming or wedging of the positive fit strip in the positive fit groove is effectively prevented.
The positive fit groove and the positive fit strip can extend over the entire length of the bottom side of the cutting tool and/or the support surface of the cutting disc. This does not rule out, however, that the positive fit groove or at least the positive fit strip may also be discontinuous. This type of embodiment of the invention advantageously has positive fit strips that engage in the positive fit groove sectionally at least in the end regions.
Another embodiment of the invention provides that the longitudinal sides of the cutting tools are made in such a way that with optional wear plates at the side surfaces of the cutting disc they effect their fixation in the desired position. Thus, the wear plates without further action are simultaneously attached to the cutting discs with the assembly of the cutting tools.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
FIG. 1 shows a vertical section through a device of the invention along the line I-I depicted in FIG. 2 ;
FIG. 2 shows a top plan view of the device depicted in FIG. 1 ;
FIG. 3 shows an oblique view of the cutting tool of the device depicted in FIGS. 1 and 2 ;
FIG. 4 shows a longitudinal section through the rotor shown in FIG. 3 ;
FIGS. 5 a and b show a first embodiment of the attachment of a cutting tool to a cutting disc in cross section and in the associated partial view;
FIGS. 6 a and b show a second embodiment of the attachment of a cutting tool to a cutting disc in cross section and in the associated partial view;
FIGS. 7 a and b show a third embodiment of the attachment of a cutting tool to a cutting disc in cross section and in the associated partial view; and
FIGS. 8 a and b show a fourth embodiment of the attachment of a cutting tool to a cutting disc in cross section and in the associated partial view.
DETAILED DESCRIPTION
FIGS. 1 to 4 show the general structure of a device of the invention in the form of a double shaft shredder 1 , which is suitable, for example, for the pre-comminuting of used tires, but also for the preparation of electronic waste and other materials. Double shaft shredder 1 has a rectangular housing 2 , which is open upward and downward and with its cross walls 5 and longitudinal walls 6 encloses a working space 7 . Housing 2 rests on a supporting frame 3 , whose top side is covered by cover plate 4 around housing 2 , to form in this manner a platform for other machine components.
A funnel-like material outlet 9 , through which the sufficiently comminuted material is discharged from double shaft shredder 1 , is connected to the lower opening of housing 2 . Feed hopper 8 , which is flush with cross walls 5 and longitudinal walls 6 and over which the feedstock is loaded into double shaft shredder 1 , is attached to the upper opening of housing 2 . Internals joining longitudinal walls 6 extend within feed hopper 8 for material charging. These include, on the one hand, a chute 10 , adjustable in inclination, and, on the other, of conveying rollers 11 , whose shafts 12 have star-shaped gripping wheels 13 and which are caused to rotate oppositely by electric drives 14 on the outside of the one longitudinal wall 6 .
The cutting tool, which performs the comminuting of the feedstock, is located in cutting chamber 7 . The cutting tool comprises substantially two rotors 15 and 16 , which are disposed at a predefined distance, axis-parallel to one another, and with an opposite rotation direction between longitudinal walls 6 . The structure of rotors 15 and 16 is a mirror image each with a drive shaft 17 , which is supported rotatable in bearings 18 disposed on the outside of longitudinal wall 6 . In each case, an end of drive shaft 17 is coupled to a hydraulic rotary drive 19 , which causes the rotation movement of each rotor 15 and 16 in the rotation direction shown by arrows.
As is evident primarily from FIGS. 3 and 4 , rotors 15 and 16 have a plurality of cutting discs 20 and spacer discs 21 , which are seated alternately on drive shaft 17 . The drive force is transferred via a positive fit between cutting discs 20 or spacer discs 21 and drive shafts 17 ( FIG. 1 ). Axis-parallel bolts 22 clamp cutting discs 20 and spacer discs 21 together.
Cutting discs 20 , which have a much larger diameter compared with spacer discs 21 , have a polygonal profile at their circumference, as a result of which support surfaces 23 with an approximate tangential course arise, which form the seat for cutting tools 24 . The specific design of support surface 23 will be dealt with in greater detail in the description of FIGS. 5 a to 8 b.
The relative position of rotors 15 and 16 to one another is such that due to an axial offset by the thickness of a spacer disc 21 , in each case a spacer disc 21 and a cutting disc 20 lie opposite each other in the radial direction. In the radial direction, the distance between axes of both shafts 17 of rotors 15 and 16 is selected so that a radial overlapping of cutting tools 23 is assured in each position of cutting discs 20 ; i.e., cutting discs 20 , equipped with cutting tools 23 , of both rotors 15 and 16 mesh together.
In this way, the longitudinal edges of cutting tools 24 form cutting edges 26 , which during the cutting process are moved past one another over the course of the opposite rotation of rotors 15 and 16 . In this regard, the structure-related axial distance between two jointly acting cutting edges 26 defines a blade clearance 27 ( FIG. 5 a ), whose size significantly determines the quality of the cutting process. Depending on the type of feedstock and other parameters, there is an optimal size for blade clearance 27 in each case, whereby deviations from this size cause the cutting process to degrade considerably. A precise positioning of cutting edges 26 relative to one another is very important for this reason.
FIGS. 5 a to 8 b show structural solutions for the positionally precise attachment of cutting tools 24 to cutting discs 20 . The embodiment shown in FIGS. 5 a and b is characterized by a positive fit strip 28 , which extends centrally over the entire length of support surface 23 at the outer circumference of cutting disc 20 . Working together with positive fit strip 28 is a cutting tool 24 , which has a complementary positive fit groove 31 on its bottom side 30 facing support surface 23 . Axial bearing surfaces on which cutting tool 24 braces during the action of axial forces against cutting disc 20 arise in this way by means of the mutually assigned side surfaces of positive fit strip 28 and positive fit groove 31 .
FIGS. 5 a and b relate to a first embodiment of the invention and thereby show the subarea, important for the invention, of a cutting disc 20 . The support area 23 is evident over whose entire length a positive fit strip 28 projects in the middle.
Cutting tool 24 substantially has a bar-shaped form and is fashioned of solid metal, preferably of hardened steel. The front end in the rotation direction is beveled, so that the top edge forms a grip tooth 29 for the secure drawing in of the feedstock. The lateral longitudinal edges at the top side of cutting tool 24 form cutting edges 26 effective for the cutting process.
A positive fit groove 31 , which is made complementary to positive fit strip 28 , runs in the center and over the entire length on the bottom side 30 of cutting tool 24 . When cutting tool 24 is placed on cutting disc 20 , a positionally precise seating therefore results by itself without further action and attentiveness by operating personnel.
Two fixing bolts 32 (indicated only by axes in FIG. 5 b ), which extend into cutting disc 20 radially through cutting tool 24 , are used to fix cutting tool 24 in its desired position on cutting disc 20 . The head of fixing bolts 32 is thereby countersunk in recesses originating on the top side of cutting tool 24 .
During operation of a device of the invention, a system of load removal thereby results, in which axial forces are taken up via the entire sides of positive fit strip 28 or positive fit groove 31 over their entire surface and transferred. Because there is a load removal surface over the entire length of cutting tool 24 thereby, greater forces overall can be absorbed and an optimal load removal behavior also results with nonuniform load applications.
In contrast, radial lifting forces are absorbed by bolts 32 alone, which tighten cutting tool 24 against cutting disc 20 . The strict separation of load removal of axial and radial forces successfully protects bolts 32 from a shearing force effect and the associated bending moment.
The attachment of cutting tools 24 to cutting discs 20 according to the invention therefore simultaneously enables a precise positioning of cutting edges 26 , optimal force transfer from cutting tools 24 to cutting disc 20 , and protection of bolts 32 from bending stress. As a result, a precise cutting geometry with high operating reliability is assured.
FIGS. 6 a and b show an embodiment of the invention, which corresponds in large parts to those described for FIGS. 5 a and b , so that the same reference characters are used for the same elements and what has been stated there corresponds accordingly.
There are differences only in the area of the positive fit between cutting tool 24 and cutting disc 20 for the precise positioning and removal of axial forces. For this purpose, positive fit strip 33 is arranged on the bottom side 30 of cutting tool 24 and engages in a positive fit groove 34 in support area 23 of cutting disc 20 .
FIGS. 7 a to 8 b relate to embodiments of the invention, which are particularly suitable in relation to wear protection for the face sides of cutting discs 20 . In the case of abrasive feedstock, circular surface 35 between spacer disc 21 and the outer circumference of cutting disc 20 is at risk for wear, for which reason it is already known to protect cutting disc 20 in the area of circular surface 35 by means of wear-resistant plates. The embodiments shown in FIGS. 7 a to 8 b combine in a special way the arrangement of cutting tool 24 on cutting disc 20 with simultaneous fixation of wear protection.
An embodiment is shown for this purpose in FIGS. 7 a and b in which cutting tools 24 have a bilateral axial overhang over cutting disc 20 and have a longitudinal base 38 projecting from the bottom side 30 and parallel to surfaces 35 . Bottom side 30 in this way forms a trough-like slot, in which cutting disc 20 comes to lie with its outer circumference with an accurate fit. Base 38 with its interior sides thus forms axially acting force transfer areas to cutting disc 20 , which assure an accurately fitting seat of cutting tools 24 on cutting discs 20 .
In addition, top sides 39 of base 38 are inclined inward, preferably at an angle of 45°, so that undercuts result, which with cutting disc 20 form spandrel-shaped slots for fixation of the wear protection.
The wear protection is formed by approximately trapezoidal plates 36 , whose lower curved edge 40 comes to lie in hollowed-out areas 41 in the edge region of spacer discs 21 . Upper edge 42 has an inclination complementary to top side 39 of base 38 , so that the pointed edge engages in the ring-shaped undercut of base 38 and is held in the axial direction. After placement and attachment of cutting tool 24 , a simultaneous attachment of plates 36 is thereby achieved.
FIGS. 8 a and b relate to an embodiment of the invention, which combines together the features of the examples shown in FIGS. 5 a, b and 7 a, b with the advantage that base 38 ′ is used only for fixation of plate 36 and therefore may be formed structurally thinner.
Support area 23 of cutting disc 20 corresponds to that described in FIGS. 5 a and b with a positive fit strip 28 , which acts together with a positive fit groove 31 in the bottom side 30 of cutting tool 24 . In addition, cutting tool 24 is made broader than cutting disc 20 , as a result of which a longitudinal base 38 ′ is formed with the overhang.
In comparison with the embodiment in FIG. 7 , the height of base 29 ′ is reduced, whereby top side 39 flush with its inner edge, therefore without a step, merges into bottom side 30 , whereas the pointed edge again forms an undercut. The attachment of plate 36 then occurs as already described in FIGS. 7 a and b.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.
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A device for comminuting feedstock is provided that includes a cutting tool with a first rotor and at least one second rotor, each of which rotate around their longitudinal axis with an opposite rotation direction. Each rotor is provided with a number of cutting discs, which are arranged at an axial distance to one another. In this case, the cutting discs of the first rotor are located on gaps and with radial overlapping relative to the cutting discs of the second rotor. The cutting discs along their circumference have support surfaces for accepting cutting tools, whose cutting edges move past one another over the course of the rotation of rotors with the formation of a cutting clearance. For the positionally precise fixation of the cutting tool on the cutting discs, a positive fit is formed between the cutting tools and cutting discs, a positive fit groove running in the plane of the cutting disc is arranged in the common contact area, the groove in which at least one positive fit strip engages.
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This is a continuation of application Ser. No. 143,340, filed Apr. 24, 1980 now abandoned.
DESCRIPTION
1. Technical Field
This invention relates in general to rotary drills for deep-well drilling and, in particular, to an improved drill bit having teeth providing improved shearing and crushing action.
2. Background of the Prior Art
In general, equipment for drilling wells and for mining dates back many centuries. Of late, such drilling equipment comprises a rotary drill string which is stabilized in the hole being drilled. The drill bit itself is on the end of this rotating shaft and, by its rotating action, cuts through the rock or other strata in which the hole is being made. Drilling fluid, usually air or mud, is circulated through the rotary drill string cooling the drill bit, simultaneously purging the core bottom. U.S. Pat. Nos. 3,302,983 and 3,659,663 show various means for stabilizing the rotary drill string within the bore, while U.S. Pat. Nos. 959,539; 1,143,272; 1,860,587 and 2,169,640 show various drill bit structures which may be utilized in boring a hole. When considering pentration rate, the method in which the formation is stressed is important. Traditionally, the rolling cutter rock bit penetrates a formation by applying a vertical pressure until it yields. The formation is stressed by a series of individual circumferentially-spaced teeth. However, it would also appear important to develop a stress sequence that not only stresses the formation vertically but laterally as well. Other factors which should be considered in increasing the efficiency, and thus the penetration rate of a drill bit, in addition to lateral pressure intensities, is the self-cleaning capability, or lack thereof, of the bit or cutter, and the capability of the bit to overcome formation strength. Other factors which are important to the structure of an effective drill bit will become apparent and are discussed below.
Therefore, an object of the subject invention is a rotary drill bit which can efficiently cut through rock with a high rate of penetration.
An additional object of the subject invention is a rotary drill bit in the shape of a cone having teeth of such a structure and relationship to one another that the penetration rate is greatly enhanced.
Yet another object of the subject invention is a drill bit which is self-cleaning during the drilling function.
Still another object of the subject invention is a roller drill bit having teeth shaped and spaced in a precise relationship for increased penetration rate and maximum cutting size.
SUMMARY OF THE INVENTION
These and other objects are attained in accordance with the present invention wherein there is provided a roller drill bit comprising two roller cone cutters which rotate on axes substantially perpendicular to one another. Each roller cutter or cone is generally frustoconical in overall shape, with a plurality of irregularly-spaced and inclined teeth. The teeth on each roller cutter are complementary, each having a lead tooth extending from the base to the apex of the roller cone cutter. In addition, the spacing between adjacent teeth increases as the cross-sectional area of the cone roller bit decreases. The respective cones are also tapered differently, aiding in the creation of dissimilar, but complementary, teeth patterns on each cone roller cutter. The teeth on each roller cone cutter are formed in planes which, viewed in cross-section along its axis of rotation, are intersecting, adding to the crushing and shearing action of the roller bit in operation.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF DRAWINGS
The foregoing and other objects, features and advantages of this invention will become apparent from the following more particular description of embodiments of the invention as illustrated in the accompanying drawings wherein:
FIG. 1 is a perspective view of a rotary drill string utilizing the rotary drill bit of the subject invention;
FIG. 2 is a perspective view of a rotary drill bit of the subject invention;
FIG. 3 is a perspective view taken along line 303 of FIG. 2 showing the teeth pattern of one rotary cone of the subject invention;
FIG. 4 is a perspective view of another rotary cone of the subject invention taken along line 4--4 showing its tooth pattern;
FIG. 5 is a cross-sectional view of the rotary cone of FIG. 3 along the line 5--5 showing the intersecting planes of the teeth of the rotary cone;
FIG. 6 is a cross-sectional view of the rotary cone of FIG. 4 showing the intersecting planes of the teeth of the rotary cone.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is shown a drill string 10 having a central shaft 20 which is stabilized for rotation by stabilizer rollers or the like as known in the art. Secured to the end of the shaft 20 is roller bit assembly 15. Rotatably mounted on the roller cone bit assembly 15 are individual cone cutters 25 and 35.
As can be better seen in FIG. 2, cutters 25 and 35 are each rotatably mounted on ears 32 and 33, respectively, through bearings mounted on seats 24 and 34 within the cone cutters. The axes of rotation of the roller cones lay approximately at a 90° angle to one another and at approximately 45° angles to normal. In the mid-portion of the roller bit assembly 15 and to either side of the roller cones are cooling fluid injection ports 30 for injecting a cooling fluid such as mud or the like for cleaning the teeth of the rotary cone bits, facilitating circulation and carrying the cuttings up and away from the bottom of the hole.
Each roller cone cutter has a configuration different from the other, although all have teeth of large size having both a large pitch and a large depth.
In particular, roller cone cutter 25, shown in FIGS. 3 and 5 has major teeth 26, 27 and 28. The planes 26a, 27a and 28a of each tooth are generally at inclined angles to a plane P1 that extends from the apex 29 of the roller cone cutter 25 to the center of the base of the cone. The general curvature of each tooth obscures much of the pattern of such inclined planes which, while generally in an upward direction towards the apex of the cone, constantly varies its degree of inclination, thereby yielding greater penetration rates, as will be discussed. In other words, each of the general tooth planes intersects with the others while the tooth contour varies within the plane. A tooth pattern is created in this manner which forms a cutting structure for formation loading which may be constant in vertical pressure intensities yet varied in lateral pressure intensities.
Roller cone cutter 35, shown in FIGS. 4 and 6, has teeth which are also at inclined angles to the plane P2 that extends from the apex of the roller cone cutter, generally shown at 39, to the center of the base of the cone. Each of these planes are intersecting and, in addition, the angle of the inclined planes are in continuous change as the plane transverses the face of the cone as a result of the irregular frustoconical shape of the cone and the shape of the tooth itself.
Roller cone cutter 35 also has three teeth 36, 37 and 38, one of which 37 is the lead tooth. Lead tooth 37 is the longest tooth on the cone 35 and also has a greater number of inclined plane combinations or changes. These plane angle changes of lead tooth 37 are complimentary, not identical, to the plane angle changes of the lead tooth 27 of roller cone cutter 25. This relationship is true for each tooth on opposing roller cone cutters. As a direct result of such complementary plane angles, in cutting through a rock formation, no tooth of either roller cone cutter ever hits a rock formation at the same angle as a following tooth. Thus, consecutive elongated craters inflicted on the rock formation will always be intersecting, creating an environment in which the formation can yield to the lateral forces that are simultaneously exerted upon it, therefore, increasing the rate of rock failure.
Contributing to the disparate planes in the roller cone cutters 25 and 35 is the fact that the cones themselves of the roller cone cutters have unequal tapers; further, as the area of the cone decreases, the spacing between the teeth increases. Further, as the area of the cone decreases, that is, as the teeth move toward the apex 29 of the cone, the spacing between the teeth increases. This increase is shown, for example, in FIG. 4 where V1 represents the distance or spacing between tooth 27 and tooth 28 at a first point relative to apex 29 and where V2 represents the distance between the same tooth 27 and the same tooth 28 at a second point closer to apex 29. Thus, the problem associated with rock cuttings migrating toward the center or apex of the cutter and compacting and plugging the teeth at the point is alleviated. The teeth actually diverge as they cross the face of the cone and, therefore, the cuttings will not migrate toward the center of the roller cone cutter and there will be no compacting of the rock material at that point or the area about the center.
In addition to the increased spacing of the teeth as they near the apex, the teeth wedge angle A (inside face angle which is the angle formed between the tooth plane or tooth face, such as 27a, and a line x drawn perpendicular to plane P1 through the base point 27x of tooth plane 27a, as shown in FIG. 5) also increases to compensate for the rapid increase in the inclined plane of the tooth as it nears the bit apex. The greater tooth wedge angle reduces the shearing action and increases crushing action of the tooth, all for maximum cuttings size and increase penetration rate. Thus, the wedge angle A of a tooth will change, as at 27, where the tooth appears to climb to the apex of the cone. In a preferred embodiment, a tooth may end abruptly as at 16 and 17, further contributing to the discontinuous nature of the rotary cone bit of the subject invention.
Another benefit of the increase in the tooth spacing toward the center of the cutter is a larger cuttings size, that is, the roller cone cutter can take a larger bite out of the formation material being penetrated. With such a larger bite, the penetration rate can be greatly increased.
As stated above, not only does the inclined plane as illustrated by planes 27a and 28 a intersecting at B of each tooth intersect and the spacing between the teeth increase, but also the plane of each tooth on a roller cone bit continually changes. As a result of such intersections of the planes and variations in the tooth spacings, the lateral pressure intensities exerted by the teeth fluctuate, thereby increasing the cuttings obtained through the rotation of the roller cone cutter. Stated another way, the teeth do not contact the formation material in the same place at the same intensity or load. Thus, a tooth may bear down on a formation material along a certain plane, simultaneously moving laterally for a greater stressing and yielding of the formation material. As the roller cone cutter rotates, it will contact the same formation material on an intersecting plane and also in a manner in which the tooth contacting the formation material will move laterally to increase the formation stressing and yielding. As the roller drill bit assembly rotates bringing the respective roller cone cutters into contact with different formation material with each rotation of the drill bit, the formation material is cratered in each pass of the roller cone cutter from a different angle, thereby increasing the penetration rate and breaking up the formation material with the maximum cuttings size.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art the various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out the invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A roller bit for use with a drill string, having at least two cutters which are generally conically shaped; each cutter includes one or more teeth in inclined planes across a conical surface. The bit is attached to the drill string with the axis of rotation of the cutter angled with respect to the longitudinal axis of the drill string. The teeth on each cutter are arranged for maximum cuttings size and penetration rate.
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GOVERNMENT INTEREST
The invention described herein may be manufactured, used, and licensed by or for the United States Government.
BACKGROUND
1. Technical Field
The disclosure generally relates to light scattering, detection, and characterizing particle systems.
2. Description of the Related Art
Light scattering can provide a non-destructive means of obtaining information about an object from a distance. As use herein, the term “light” refers to electromagnetic radiation over the entire electromagnetic spectrum including, but not limited to, visible light, ultraviolet light, infrared light, and near infrared light. The object can be a surface, like that of the Earth observed from space or of a computer wafer in a clean-room environment. The object can also be a cloud consisting of smoke, ice crystals, pollutants, biological agents, or any number of other things about which information is desired. In many scattering configurations, the light source and detector are in close proximity. For instance, in monitoring the atmosphere for a cloud of particles using Light Detection and Ranging (LIDAR), a laser and a detector located on the same apparatus are used. This is primarily for convenience, as it requires only one physical station to set up for instrumentation. In addition, for observations from a distance it makes alignment much simpler. When the source and the detector are each separate instruments, they cannot simultaneously detect and receive light at the same location as there is always some physical separation between them; therefore, the light that scatters from the object of interest cannot be measured by the detector in the exact backscatter direction, which is located 180 degrees from forward scatter. It is measured at some finite angle β, the backscatter angle, measured from the exact backscatter direction. This finite angular extent can have implications in the interpretation of the resulting data.
Various physical phenomena occur when light traveling from a source to an object is scattered back in the direction of the source, i.e., in the backscatter region. In sensing terrain, for instance, no shadows are seen in the exact backscatter direction, but as β increases, shadows will become visible that will reduce the signal on the detector. This is sometimes referred to as the shadowing effect. This shadowing contains information on the morphology and polydispersity of the particles in the sample. In addition, multiple scattering of rays by points on the object causes the rays to interfere with each other. In the backscatter region, rays that travel reciprocal paths interfere constructively, resulting in an increase in signal intensity on the detector. This is sometimes referred to as the coherent backscattering effect or backscattering surge. Accompanying the coherent backscattering effect is the polarization opposition effect—light has zero polarization in the exact backscatter region, but has a negative polarization state at angles slightly off the exact backscatter direction The amount of signal intensity increase in the backscatter region and the rate of fall-off of the polarization are determined by the morphological and chemical properties of the object; hence, a measurement of these light-scattering properties contains important information about the object.
The properties of the absolute intensity and rate of change of intensity and polarization state in the backscatter region are of interest for characterizing objects. Most remote-measuring techniques like LIDAR do not measure light in the exact backscatter direction (β=0), so it is difficult to interpret the information that is retrieved. In addition, it is desirable to know the scattering properties as a function of backscatter angle β, i.e. to have measurements at multiple angles across the backscatter region. One way of decreasing the angle β is to make the distance to the object extremely large or to reduce the distance between the source and the detector; however, β still remains finite.
SUMMARY
Systems for measuring backscattered light are provided. In this regard, an exemplary embodiment of a system comprises the following: a light source operative to output light; a mirror, operative to rotate with a rotational frequency, such that the light from the light source is reflected by the mirror toward the sample and backscattered light, corresponding to the light from the light source and scattered from the sample, is reflected by the mirror; and a detector operative to receive the backscattered light reflected from the mirror.
Other systems, methods, features and/or advantages of this disclosure will be or may become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features and/or advantages be included within this description and be within the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1A shows an exemplary embodiment of a system for measuring backscattered light.
FIG. 1B shows another exemplary embodiment of a system for measuring backscattered light.
FIG. 2 shows another exemplary embodiment of a system for measuring backscattered light.
DETAILED DESCRIPTION
Systems for measuring backscattered light are provided, and several exemplary embodiments will be discussed in detail. In this regard, embodiments may be used for measuring the spatial relationship between objects at a distance. Additionally or alternatively, some embodiments may be used to provide information about the size distribution and/or chemical properties of particles in a sample.
FIG. 1A shows an exemplary embodiment of a system for measuring backscattered light that incorporates a light source 101 , a rotating mirror 104 , and a detector 102 . The mirror 104 rotates at a rotational frequency f. Light from the source 101 is directed to the mirror 104 , which reflects the light toward a sample 103 . The sample 103 scatters the light. The exactly backscattered (β=0) light propagates back toward the mirror 104 . During the time interval in which the light propagates to the sample and back to the mirror, mirror 104 has rotated. Thus, the mirror is positioned to reflect the exactly backscattered light (β=0) to the detector 102 instead of back to the source 101 . Notably, the detector is positioned to correspond to the range of the sample and the rotation frequency of the mirror. In this way, the light in the exact backscatter region may be measured. In some embodiments, the rotational frequency of the mirror is adjustable to reflect the backscattered light at different backscattering angles to the detector.
The detector 102 may obtain measurements for a range of values of backscatter angle β. In one embodiment, this is achieved by varying the rotational speed f of the mirror 104 . As the rotational speed of the mirror varies, the amount of rotation of the mirror that occurs while the light propagates from the mirror to the sample and back to the mirror also varies, resulting in backscattered light with varying values of β being reflected to the detector. The backscattering angle β at a detector 102 , located at distance d 4 from the source 101 , is given by β˜(d 4 −8πfd 3 d 3 /c)/(d 2 +d 3 ), where f is the rotational frequency of the mirror 104 , d 2 is the distance between mirror 104 and sample 103 , c is the speed of light, and d 3 is the distance between detector 102 and mirror 104 .
In another embodiment, shown in FIG. 1B , multiple detectors 102 -B 1 , 102 -B 2 , and 102 -B 3 are positioned in multiple locations in the backscatter region; these locations correspond to different values of β. Alternatively, a single detector 102 may be moved to various locations across the backscatter region during operation, as shown by locations 102 -B 1 , 102 -B 2 , and 102 -B 3 in FIG. 1B . At each location backscattered light is measured for a different value of β, or, alternatively, different ranges of the sample for a given β. FIG. 1B is not limiting; the number of detectors and detector locations may vary depending on the application. As above, the backscattering angle β at any detector 102 , located at distance d 4 from the source 101 , is given by β˜(d 4 −8πfd 2 d 3 /c)/(d 2 +d 3 ), where f is the rotational frequency of the mirror 104 , d 2 is the distance between mirror 104 and sample 103 , c is the speed of light, and d 3 is the distance between detector 102 and mirror 104 .
In another embodiment, a pulsed laser with a frequency corresponding to the rotational frequency f of the mirror 104 is used as the source 101 . The phase lag of the pulsed laser relative to rotational frequency f may be adjusted to scan across the sample 103 by timing the laser to reflect from the mirror at various points in the mirror's rotation, thereby illuminating different points on the sample. The detector may be a charge-coupled device (CCD) detector, which measures angular extent, in addition to exact backscattering. Also, the mirror may be of sufficiently high quality so as not to corrupt the state of the reflected light significantly. By way of example, a mirror exhibiting roughness <λ/10, where λ is the wavelength of the incident light, should be sufficient for most applications where the samples are irregular surfaces with roughness significantly greater than λ.
Some embodiments may be used for remote sensing, for example LIDAR. By way of example, in remote-sensing mode, the sample may be located a large distance d 2 from the mirror. Because of the large distance, the distance d 1 between the source and the rotating mirror may be made small, and it is possible to physically locate the source, detector, and mirror in one structure. In such an embodiment, the angle β is greatly reduced due to the relatively small size of the mirror in relation to the distance between the sample 103 and mirror 104 . Other embodiments may be used for sample characterization; the sample in these embodiments is located a short distance d 2 from the mirror. Because of the small d 2 , the distance d 1 between the mirror and the source must be relatively large. In this case, the angle β can be made large. In this embodiment, the device may comprise two physical apparatuses. The source and detection components may be located together in one structure, and the rotating mirror may be contained in a separate structure, as it should be a relatively large distance from the source and detection components.
The light emitted from the source may be treated to reduce stray signals and ensure that angular divergence is reduced. FIG. 2 shows an embodiment of a system for measuring backscattered light using optics for this purpose. As shown in FIG. 2 , the light emitted from source 201 is collimated by a spatial filter assembly 205 , resulting in all the rays being incident on the sample. This reduces the divergence of the light, which tends to reduce the error in the measured backscatter angle. A diaphragm or field stop 208 adjusts the size of the illuminated area of the sample. Polarization filters 206 can be inserted at the source to control polarization characteristics of the light from the source. An optical modulator 207 is used to adjust the polarization state and also to modulate the light from the source to reduce noise. Polarizers or quarter-wave plates 213 and 212 , can be placed in front of the source 201 and the sample 203 , respectively, adjust the polarization state of the light. A lock-in amplifier 214 can be used to amplify the source signal; the phase of the lock-in amplifier may be adjusted in conjunction with the rotation frequency f of the mirror to scan across the sample and the backscatter region. Depending on the information sought regarding sample 203 , various embodiments may comprise any combination of the forgoing optics to treat the light from the source 201 .
Further embodiments have optics inserted at detector 202 to increase the signal-to-noise ratio or to detect light at particular polarization states. Again referring to FIG. 2 , a diaphragm and lens 210 reduce stray light. The lens is preferably placed so that its focal point is on the detector plane, so that parallel rays of light are detected; i.e., light rays that are scattered in the same direction. A spatial filter assembly may be used in place of the diaphragm 208 and lens 210 . A polarizer 211 may be included to select the polarization state of the detected light, allowing measurement of the intensity of a particular polarization state. A lock-in amplifier 209 may also be included to reduce the noise from external light sources; the lock-in amplifier may be modulated with the frequency f of the rotating mirror 204 , with the pulse frequency of the source laser 201 , or with an optical modulator 207 placed at the source 201 to scan across the sample. Apertures 215 may also be inserted at the detector to limit the field of view of the detector 202 . Depending on the information sought regarding sample 203 , various embodiments may comprise any combination of the forgoing optics to treat the light received at the detector 202 .
Preferably, the light used in the present invention includes visible light, ultraviolet light or infrared light More preferably, the light is or includes visible light or infrared light. Most preferably, the light is or includes visible light or near infrared light.
It should be emphasized that the above-described embodiments are merely possible examples of implementations set forth for a clear understanding of the principles of this disclosure. Many variations and modifications may be made to the above-described embodiments without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the accompanying claims.
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A system for measuring backscattered light from a sample is given. Light is output from a light source towards a rotating mirror, and then reflected by the rotating mirror towards the sample. The sample reflects backscattered light back towards the rotating mirror, which, having moved during the time it took for the light to propagate from the mirror to the sample and back, reflects the backscattered light to a detector located at a physical separation from the light source. The detected backscattered light may be analyzed to determine various properties of the sample.
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CROSS-REFERENCE AND RELATED APPLICATION
This application claims priority on Chinese patent application no. 201210398345.8 filed on Oct. 18, 2012. The contents and subject matter of the priority application is incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a novel reaction system and process for continuous production of polyoxymethylene dialkyl ethers, particularly, via continuous acetalation between formaldehyde and an aliphatic alcohol in the presence of an acid ionic liquid catalyst.
BACKGROUND OF THE INVENTION
Polyoxymethylene dialkyl ethers (RO(CH 2 O) n R) are novel blending components for clean oil product, which have very high cetane number (H 3 CO(CH 2 O) 2 CH 3 : 63, H 3 CO(CH 2 O) 3 CH 3 : 78, H 3 CO(CH 2 O) 4 CH 3 : 90, H 3 CO(CH 2 O) 5 CH 3 : 100, H 5 C 2 O(CH 2 O) 2 C 2 H 5 : 77, H 5 C 2 O(CH 2 O) 3 C 2 H 5 : 89) and oxygen content (methyl series: 42%-49%, ethyl series: 30%-43%). When polyoxymethylene dialkyl ethers are added to the diesel oil at 10%-20%, it significantly improves the combustion characteristic of the diesel oil, increases the thermal efficiency, and greatly reduces the emission of NO x and soot. Therefore, polyoxymethylene dialkyl ethers are considered as very promising environment-friendly diesel blending components. U.S. Pat. No. 7,235,113 discloses that when 15% of H 3 C(OCH 2 ) 3-6 OCH 3 is added to the diesel oil, the emission of NO x , particles, and hydrocarbon of the exhaust achieves Euro V standard.
EP 1505049 A1 and U.S. Pat. No. 6,534,685 by Snamprogetti S.P.A. Corporation disclose a process for synthesizing polyoxymethylene dimethyl ethers (DMM n ) and recycling the materials, where the acetalation reaction between polyformaldehyde and methylal under the catalysis of liquid acid produces DMM 2-5 , the reaction solution is absorbed via silica gel column to remove the liquid acid catalyst, the treated reaction solution enters the rectification column, the light components (trioxymethylene, DMM 1-2 ), the products (DMM 3-5 ), and the heavy components (DMM ≧5 ) are separated using two-stage rectification process, and the light components and the heavy components are recycled to the reactor for reuse. PCT Publication WO 2006/045506 A1, Canadian Patent Application Publication CA 2581502 A1, U.S. Patent Application Publication Nos. 20070260094 A1 and 20080207954 A1, by BASF Corporation, disclose similar catalysts and products separation process in which the reaction between trioxymethylene and methanol catalyzed by the liquid acid produces DMM 1-10 and byproduct water. The reaction solution is subject to the absorption through the packed column charged with the anion exchange resin to remove the acid and water, the treated reaction solution enters the rectification column, and the products DMM 3-4 are separated through three-stage rectification, where DMM n with n≦2 and n≧5 are recycled to the reactor for reuse. The above reaction solution separation process employs large amount of absorbents, thereby resulting in high energy consumption, and the catalyst cannot be reused.
U.S. Patent Application Publication No. 20080207954 A1 by BASF Corporation discloses a process of producing DMM 1-5 through the reaction of methanol and formaldehyde in an aqueous solution catalyzed by a liquid acid or a solid acid, where a reaction rectification technique is employed for separating the crude products (DMM 1-5 , raw materials, and water) and the catalyst, and the crude products are separated into the light components (DMM 1-2 and unreacted raw materials), the products DMM 3-4 (containing water), and the heavy components DMM >4 by a multi-stage rectification process. But in the actual operation of the process, it is difficult to separate methanol and DMM 3-4 due to the azeotrope of methanol, water, and DMM n . Meanwhile, the good miscibility of methanol, water, and DMM 3-4 causes phase separation more difficult.
Recently, Lanzhou Institute of Chemical Physics, Chinese Academy of Sciences, in U.S. patent application Ser. No. 13/154,359 and published as U.S. Patent Application Publication No. 20110288343 A1, UK Application No. 1108697.2 and published as GB 2489534A, U.S. patent application Ser. No. 13/164,677 and published as U.S. Patent Application Publication No. 20110313202 A1, and UK Application No. 1110391.8 and published as GB2483325A, discloses a method of synthesizing DMM 1-8 through the reaction of trioxymethylene and methanol catalyzed by ionic liquids, where the reaction solution is subjected to flash evaporation, film separation, and phase separation to separate the light components (DMM 1-2 , a part of water, unreacted raw material), the crude products DMM 3-8 , and catalyst. In order to achieve the purification of the products DMM 3-8 , small amount of water and catalyst contained in the crude products need to be removed by absorption with silica gel or anion exchange resins, thus, the recovery rate of catalyst of the process is relatively low.
SUMMARY OF THE INVENTION
The invention provides a process for producing polyoxymethylene dialkyl ethers via the continuous acetalation reaction of formaldehyde and aliphatic alcohol by using an acid ionic liquid as a catalyst, where the polyoxymethylene dialkyl ethers are represented by RO(CH 2 O) n R where R is CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , or CH(CH 3 ) 2 , and n is an integer ranging from 1 to 8.
In the first aspect, the invention provides a system for continuously producing polyoxymethylene dialkyl ethers (also hereinafter referred to as “the system of the invention”), comprising:
1) an acetalation reaction unit, comprising a single or multi-stage reactor and a heat exchanger, where the reactor is in flow communication with the heat exchanger, and the reaction solution circulates between the reactor and the heat exchanger; wherein an acetalation reaction between the formaldehyde and the aliphatic alcohol is continuously conducted using an acid ionic liquid as a catalyst in the single or multi-stage reactor;
2) a product separation unit, comprising an extraction column and a single or multi-stage rectification column connected to each other in series; wherein a light phase and a heavy phase are extracted from a reactor effluent discharged from the acetalation reaction unit by using an extractant in the product separation unit, wherein the light phase is a product phase containing recyclable materials, the extractant and the products RO(CH 2 O) 3-8 R wherein R is CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , or CH(CH 3 ) 2 ; and the heavy phase is an aqueous catalyst solution;
3) a catalyst regeneration unit, comprising a film separator; wherein the catalyst regeneration unit receives the heavy phase separated from the product separation unit, and the catalyst in the heavy phase is recycled to the acetalation reaction unit after dehydration.
In one embodiment of the system of the invention, the single or multi-stage reactor is a single or multi-stage tubular reactor or an overflow tank.
In another embodiment of the system of the invention, the rectification columns in the product separation unit include a light components rectification column, an extractant rectification column, and a product rectification column
In one embodiment of the system of the invention, the rectification columns used in the system are tray columns or packed columns having a plate number of 3-10.
In one embodiment of the system of the invention, the film separator in the catalyst regeneration unit is selected from a falling film evaporator, a wiped thin film evaporator, or a thin film evaporator.
When the method of the invention is carried out in the system of the invention, the following acid ionic liquids are chosen: the cation moiety of the acid ionic liquids is one selected from a quaternary ammonium cation, a quaternary phosphinium cation, an imidazolium cation, an pyridinium cation, or other heterocyclic cations, and the anion moiety of the acid ionic liquids is one selected from p-toluene sulphonate, trifluoromethyl sulphonate, methyl sulphonate, bisulfatem, or trifluoroacetate.
In a second aspect, the invention provides a method for continuously producing polyoxymethylene dialkyl ethers (hereinafter, is also simply described as “the method of the invention”), comprising the following steps:
1) continuously conducting the acetalation reaction of formaldehyde and aliphatic alcohol at about 100-150° C., about 1.0-5.0 MPa under the protection of nitrogen by using an acid ionic liquid as a catalyst; wherein the resulting reaction effluent contains the produced polyoxymethylene dialkyl ethers and water, as well as the unreacted reaction raw materials and the catalyst;
2) extracting a light phase and a heavy phase from the reaction effluent obtained in step 1) using an extractant, wherein the light phase is a product phase containing the recyclable materials, the extractant and the products RO(CH 2 O) 3-8 R wherein R is CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 or CH(CH 3 ) 2 ; and the heavy phase is the aqueous catalyst solution;
3) separating most of the water from the aqueous catalyst solution in the heavy phase from step 2) by evaporation, the recovered catalyst is returned to step 1) for reuse.
In the method of the invention, the cation moiety of acid ionic liquids are one selected from a quaternary ammonium cation, a quaternary phosphinium cation, an imidazolium cation, a pyridinium cation, and other heterocyclic cations, while the anion moiety of the acid ionic liquids are one selected from a p-toluene sulphonate, a trifluoromethyl sulphonate, methyl sulphonate, bisulfate and trifluoroacetate.
In one preferred embodiment of the method of the invention, the total amount of the acid ionic liquid catalyst is about 1-5 wt. % of the total reaction materials.
In another preferred embodiment of the method of the invention, the formaldehyde used in step 1) is selected from the aqueous formaldehyde solution, polyformaldehyde, or trioxymethylene. When the aqueous formaldehyde solution is used, the concentration thereof is preferably about 37-90 wt %.
In one preferred embodiment of the method of the invention, the aliphatic alcohol used in step 1) is selected from methanol, ethanol, propanol, or isobutanol, preferably methanol or ethanol.
In another preferred embodiment of the method of the invention, the molar ratio of the formaldehyde to the aliphatic alcohol used in step 1) is about 0.9-3.0.
In one preferred embodiment of the method of the invention, the reaction pressure in step 1) is about 2.0-4.0 Mpa, and the reaction residence time is about 30-60 min
In another preferred embodiment of the method of the invention, the extractant used in step 2) is one or more extractant(s) selected from n-hexane, cyclohexane, petroleum ether, chloroform, benzene, toluene, xylene, or ethyl acetate, preferably cyclohexane, benzene, or toluene.
In one preferred embodiment of the method of the invention, the amount of the extractant used in step 2) is 1-3 times more than the volume of the reaction solution. In another preferred embodiment of the method of the invention, the extraction temperature in step 2) is about 25-80° C., preferably about 30-40° C.
In one preferred embodiment of the method of the invention, the evaporating temperature in step 4) is about 20-100° C., preferably about 60-80° C., and the vacuum degree is about from −0.1 MPa to −0.01 MPa, preferably about from −0.05 MPa to −0.02 MPa.
In the system and method of the invention, the recyclable materials separated by rectification in the product separation unit or step 2) specifically include the unreacted reaction raw materials (formaldehyde and aliphatic alcohol), and RO(CH 2 O) 1-2 R.
The process parameters and reaction materials such as feedstocks, extractants, and catalysts, used in the method of the invention may also be applied to the system of the invention.
The invention provides the following advantages:
first, the invention employs an extraction separation process, which effectively separates the catalyst and the products, and the recovery rate of the catalyst is 99% or more;
second, the invention effectively separates the byproduct water from the products RO(CH 2 O) 1-8 R, as well as the reaction raw materials aliphatic alcohol and formaldehyde, destroys the azeotrope of the water with RO(CH 2 O) n R, alcohols, and aldehydes, and thus effectively separates the products; and
third, the work up of the catalyst solution is easy, achieving the regeneration and recycling of the catalyst.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram showing the device configuration and process flow in one embodiment of the present invention for continuously producing the polyoxymethylene dialkyl ethers by condensation reaction.
FIG. 2 is a flow chart showing the flow direction of the reaction material streams in one embodiment of the method of the present invention.
The figures are only used for describing the schematic process flow of the technical solution of the invention, where only the necessary devices for explaining the process are drawn. For simplicity and clarity, the other necessary devices are omitted, such as meters, gas bus devices, pumps, valves, and intermediate tanks, etc.
DETAILED DESCRIPTION OF THE INVENTION
The technical process of the invention is illustrated in association with the devices used in the method of the present invention as follows (hereinafter, A, B, and C zones correspond to the zones noted by the reference signs A, B, and C in FIG. 1 , respectively):
A. In the reaction zone A (corresponds to the “acetalation reaction unit” of the system of the invention), with the acid ionic liquid as the catalyst, an acetalation reaction between formaldehyde and aliphatic alcohol are continuously conducted under the protection of nitrogen; the devices configured in the reaction zone may include a single or a multi-stage tubular reactor and a heat exchanger, wherein the reactor is in flow communication with the heat exchanger, and the reaction solution is recycled in the reactor and the heat exchanger.
B. In the product separation zone B (corresponds to the “product separation unit” in the system of the invention), the devices configured in this zone may include an extraction column and a single or a multi-stage rectification column connected to each other in series; the reactor effluent flowed out from the above reaction zone is lowered in pressure, continuously flows into the extraction column where RO(CH 2 O) 1-8 R, wherein R is CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , or CH(CH 3 ) 2 , and the most of reaction raw materials are extracted by an extractant. The extract liquor continuously flows into the rectification unit, where the recyclable materials, extractant, and products RO(CH 2 O) 3-8 R are separated. The aqueous catalyst solution continuously flows into the catalyst regeneration zone.
C. In the catalyst regeneration zone C (corresponding to the “catalyst regeneration unit” in the system of the invention), a film separator may be provided. The aqueous catalyst solution from the product separation zone is continuously fed into the film separator, where most of the water is separated, and the catalyst continuously flows into the reaction zone for reuse.
The technical process of the method of the invention is specifically described below.
The reaction formula employed in the method of the invention is represented as follows:
wherein:
R in the reaction formula is CH 3 , CH 2 CH 3 , CH 2 CH 2 CH 3 , or CH(CH 3 ) 2 , n is an integer ranging from 1 to 8, IL represents an acid ionic liquid catalyst.
As for the acid ionic liquid catalysts used in the invention, it may be chosen with reference to the following preferred examples.
The structure of the examples of the quaternary ammonium cation of the acid ionic liquid catalyst employed in the invention may be:
wherein: n and m are integers of 1-15; R, R 1 , and R 2 are linear alkanes having a carbon number of 1-6 or benzene rings; X is −SO 3 H or —COOH.
The structure of the examples of the quaternary phosphinium cation of the acid ionic liquid catalyst employed in the invention may be:
wherein: n and m are integers of 1-15; R, R 1 , and R 2 are linear alkanes having a carbon number of 1-6 or benzene rings; X is —SO 3 H or —COOH.
The structure of the examples of the imidazolium cation of the acid ionic liquid catalyst employed in the invention may be:
wherein: n and m are integers of 1-15; R is a linear alkane having a carbon number of 1-6 or a benzene ring; X is —SO 3 H or —COOH.
The structure of the examples of the pyridinium cation of the acid ionic liquid catalyst employed in the invention may be:
wherein: n and m are integers of 1-15; R is a linear alkane having a carbon number of 1-6 or a benzene ring; X is —SO 3 H or —COOH.
The structure of the examples of the heterocyclic cation of the acid ionic liquid catalyst employed in the invention may be:
wherein: n and m are integers of 1-15; R is a linear alkane having a carbon number of 1-6 or a benzene ring; X is —SO 3 H or —COOH.
Examples of the anion of the acid ionic liquid catalyst employed in the invention may include:
CH 3 PhSO 3 − , CF 3 SO 3 − , CH 3 SO 3 − , HSO 4 − , CF 3 COO − .
It should be noticed here that, unless otherwise specified, all of the pressures used herein represent gauge pressure; furthermore, the description of the following process may relates to devices not shown in the figures, as stated above, these devices are only omitted for the reason of simplicity and ease of describing and illustrating the main configuration of the system of the invention, instead of indicating that these devices are absent or unnecessary. In addition, it should be understood that, the following description and examples are only the preferred embodiments for illustrating the invention, which is not intended to limit the scope of the invention, therefore the devices used in the system of the invention do not only limited to the specific devices mentioned below. Without further elaboration, it is believed that one skilled in the art can choose the suitable devices with the similar function according to the specific situation based on the teaching of the invention.
The process flow of the method of the invention is described below in associated with the specific configuration of the process devices shown in FIG. 1 and the flow direction of the material streams shown in FIG. 2 .
(1) When the reaction starts or the catalyst is supplemented, the ionic liquid catalyst is added via pipe-line 4 into a catalyst storage tank V 3 , and then after fed into a reactor R 1 via pump, it is recycled to the whole system.
(2) Acetalation reaction: the whole system is purged with N 2 , the oxygen content detected by the discharged exhaust gas detecting system is lower than 10 ppm. The reaction raw materials, formaldehyde or trioxymethylene and aliphatic alcohol, are charged into raw material storage tanks V 1 and V 2 via pipe-line 2 and pipe-line 3 , respectively. The reaction raw materials are metered by a liquid mass velocity meter (not shown in the Figures) via pipe-line 5 , the light components recycled via pipe-line 22 and the catalyst solution recycled via pipe-line 15 , respectively, are metered and continuously flow into the acetalation reactor R 1 . N 2 is cleaned through a cleaning unit, and metered into the reactor R 1 via pipe-line 1 . The acetalation reaction occurs at certain temperature and pressure. The effluent stream from the bottom of the reactor R 1 is transferred through pipe-line 8 , by means of pump P 1 , and into a heat exchanger V 6 , then returned to the reactor R 1 through pipe-line 9 . The reactor R 1 in flow communication with the heat exchanger V 6 , and the reaction solution is circulated between the reactor R 1 and the heat exchanger V 6 . The overhead stream from the reactor R 1 comprises the catalyst, RO(CH 2 O) 1-8 R, water, unreacted aliphatic alcohol and formaldehyde or trioxymethylene.
(3) Extraction separation: the effluent of the reactor R 1 is fed into a heat exchanger V 7 via pipe-line 10 , followed by cooling down and lowering the pressure, it is transferred through pipe-line 11 into an extraction column V 8 . The extractant is supplied from a storage tank V 5 via pipe-line 12 , and into the extraction column V 8 , where the reaction solution is conversely and sufficiently contacted with the extractant. The light phase (product phase) continuously enters a rectification column V 9 from the head of the column via pipe-line 13 , and the heavy phase (aqueous catalyst solution) continuously enters a film evaporator V 12 from the bottom of the column via pipe-line 14 .
(4) Rectification separation: the product phase containing RO(CH 2 O) 1-8 R, the extractant, unreacted aliphatic alcohol and formaldehyde is rectified in the rectification column V 9 . The light components continuously distilled from the head of the column (mainly containing formaldehyde, aliphatic alcohol, and ROCH 2 OR) are returned to the reaction system via pipe-line 16 after cooling down. The bottom liquid is fed into a rectification column V 10 via pipe-line 17 , and the extractant distilled from the head of the column is returned to the extractant storage tank V 5 via pipe-line 18 for reuse; the bottom liquid enters a rectification column V 11 via pipe-line 19 , RO(CH 2 O) 2 R and trioxymethylene are distilled from the head of the column via pipe-line 20 and returned to the reaction system for reuse, and the bottom effluent products RO(CH 2 O) 3-8 R enter a product storage tank via pipe-line 21 .
(5) Catalyst dehydration: the aqueous catalyst solution is continuously fed from the bottom of the extraction column via pipe-line 14 into a film evaporator V 12 . Flash distillation is conducted at from about 60 to 80° C./from about −0.05 to −0.02 MPa for dehydrating, and the catalyst is recovered to the catalyst storage tank V 4 via pipe-line 15 .
Production examples are provided as follows with reference to the configuration of FIG. 1 and the flow direction of the material streams in FIG. 2 .
EXAMPLES
The catalysts used in the examples are as follows:
Example 1
In the reaction process shown in FIG. 1 , the volume of the reactor R 1 is 1000 mL, the reactor R 1 is in flow communication with the heat exchanger, and the reaction solution is recycled in the reactor and the heat exchanger.
The system was purged with high-purity nitrogen to replace air. Ionic liquid catalyst I was fed into the fluidized reaction system. The feeding speed was 1.0 g/h. The feeding was stopped until the catalyst begins to be circulated, so that the concentration of the catalyst was ensured to be not less than 4%. Trioxymethylene with a purity of 98.5 wt %, and the methanol with a purity of 99% were charged under the feeding speed of 15.0 mL/h and 100 mL/h, respectively into the reactor R 1 to conduct the reaction. The operating condition of the reactor R 1 was controlled at 115-120° C. and 2.5-3.5 MPa.
The reaction solution is fed into the extraction column V 8 , and the feeding speed of the extractant benzene is 25 mL/h The heavy phase (i.e., an aqueous catalyst solution) continuously entered the film evaporator V 12 from the bottom of the column, it was dehydrated at 60° C./−0.05 MPa, and the catalyst was fed into the reactor for reuse. The light phase (i.e., the product phase) continuously entered the rectification column V 9 from the head of the column Light components comprising CH 3 OCH 2 OCH 3 , formaldehyde, and methanol were continuously distilled from the head of the column at 40-60° C., directly returned to the reaction unit A for reuse. The bottoms were fed into the rectification column V 10 , where the extractant benzene was distilled from the head of the column at 78° C.-80° C. and returned back to the storage tank V 5 for reuse; the bottoms entered the rectification column V 11 , where CH 3 O(CH 2 O) 2 CH 3 and trioxymethylene were distilled from the head of the column at 98-110° C. and returned back to the reaction unit for reuse. The products CH 3 O(CH 2 O) 3-8 CH 3 discharged from the bottom of the column entered the product storage tank. The reaction solution, extraction liquid, aqueous catalyst solution, and products were sampled at regular time and the samples were quantitatively analyzed with a gas chromatograph. The acetalation reaction continues for 100 h. The results of the experiment are shown in Table 1.
TABLE 1
The pipe-line
Discharge
Products distribution (%)
where the
speed
CH 3 O(CH 2 O) n CH 3 n =
sampling point is
mL/h
benzene
methanol
trioxymethylene
water
1
2
3
4
5
6
7
8
11
25.8
0
2.9
2.3
6.4
28.2
30.5
20.7
10.5
3.9
0.8
0.2
0
13
47.3
45.1
1.5
1.2
0.3
15.5
16.7
11.4
5.8
2.1
0.4
0.1
0
14
2.7
5.8
0.2
0.1
59.0
0.2
0
0
0
0
0
0
0
21
9.0
0
0.1
0.2
0.05
0
4.2
51.3
30.0
10.7
3.0
0.5
0
Note:
the extracted aqueous catalyst solution (14) contains catalyst in 37.0%.
Example 2
The basic process steps and the configuration of the devices were the same as Example 1, except that the ionic liquid II was added as the catalyst, the feeding speed was 0.6 g/h. The feeding was stopped until the catalyst begins to be circulated; the reaction materials were 80 wt % of aqueous formaldehyde solution, and methanol with a purity of 99%, and the feeding speed was 10.8 mL/h and 5.8 mL/h, respectively. The operating condition of the reactor R 1 was controlled at 125-130° C., and 3.5-4.0 MPa. The acetalation reaction ran continuously for 100 hours. The results are shown in Table 2.
TABLE 2
The pipe-line
Discharge
Products distribution (%)
where
speed
CH 3 O(CH 2 O) n CH 3 n=
the sampling point is
mL/h
benzene
methanol
formaldehyde
water
1
2
3
4
5
6
7
8
11
17.0
0
2.4
5.1
19.3
29.1
26.2
11.6
3.5
1.9
0.5
0
0
13
29.5
52.3
1.3
2.7
0.2
16.8
15.2
7.6
2.0
1.0
0.3
0
0
14
4.5
5.4
5.5
2.0
66.7
6.7
0.4
0
0
0
0
0
0
21
3.0
0
0.3
0
0.05
0.1
1.2
59.5
26.8
9.8
2.6
0
0
Note:
the extracted aqueous catalyst solution (14) contains catalyst in 13.3%.
Example 3
The basic process steps and the configuration of the devices as well as the parameters thereof were the same as Example 1, except that toluene was used as the extractant. The reaction ran continuously for 100 hours, resulting in 9.1 mL/h of DMM 3-8 product (from pipe-line 21 ).
Example 4
The basic process steps and the configuration of the devices as well as the parameters thereof were the same as Example 1, except that the amount of the extractant was one time more than the volume of the reaction solution. The reaction ran continuously for 100 hours, resulting in 8.8 mL/h of DMM 3-8 product (from pipe-line 21 ).
Example 5
The basic process steps and the configuration of the devices as well as the parameters thereof were the same as Example 1, except that the molar ratio of the trioxymethylene to the methanol was 0.5:1. The reaction ran continuously for 100 hours, resulting in 9.2 mL/h of DMM 3-8 product (from pipe-line 21 ).
Example 6
The basic process steps and the configuration of the devices as well as the parameters thereof were the same as Example 1, except that the amount of catalyst IL II was 2 wt. % of the total charge amount. The reaction ran continuously for 100 hours, resulting in 7.3 mL/h of DMM 3-8 product (from pipe-line 21 ).
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A reaction system and method for producing polyoxymethylene dialkyl ethers (RO(CH 2 O) n R, n=1-8) by continuous acetalation of formaldehyde and aliphatic alcohol in the presence of an acid ionic liquid catalyst. The reaction system includes an acetalation reaction unit, a product separation unit, and a catalyst regeneration unit. The recyclable material and catalyst are separated by combining extraction and rectification, and a recovery rate of more than 99% for the catalyst is achieved. Water, as the byproduct, is separated from the reaction system by destroying the azeotrope of water, alcohol, aldehyde, and RO(CH 2 O) n R, so that the product separation and catalyst regeneration are facilitated and the catalytic cycle is achieved.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] “Not Applicable”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] “Not Applicable”
REFERENCE TO A MICROFICHE APPENDIX
[0003] “Not Applicable”
BACKGROUND OF THE INVENTION
[0004] This patent application follows the provisional application No. 60/472,092 with the filing date May 21, 2003, titled, “Means to increase water velocity through a hydro electric turbine”.
[0005] The method of using a venturi to increase the velocity of a water flow is old. The embodiment has the following aspects which the inventor believes are new.
1) The front shroud is flexible (collapsible) on demand. 2) The front shroud can be pursed (drawn) together to stop water from flowing through it and the turbine. 3) The purse line can be released to allow water to flow through the front shroud and turbine. 4) A combination of a flexible front and a rigid rear shroud used together as one unit. 5) The method of pursing a flexible shroud to stop the rotation of a turbine. 6) The method of using a flotation chamber to raise a turbine to the surface to be serviced.
BRIEF SUMMARY OF THE INVENTION
[0012] One of the problems inherent in a low head (run of the river, tidal, etc.) turbine for producing electricity is the relatively slow water velocity; usually from 1 to 5 knots. This device that incorporates 2 shrouds (one front, one rear) increases the water velocity flowing through the turbine.
[0013] This ability to increase low head water velocities to those of high head applications has inherent advantages of cost, size, efficiency and overall maintainability. Since horsepower output is on an exponential curve with water velocity, it is expedient to keep the blade diameter as small as possible to reach the goal power output. This embodiment does that by the use of shrouds. Overall cost per kilowatt hour is lower when shrouds are used since the shrouds are the least expensive component of the machine.
[0014] The collapsible front shroud, when pursed, provides a rapid means of shutting down the turbine.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0015] FIG. 1 shows the front and rear shroud with the turbine section between. The cables to the flotation chamber are cut at match line (A).
[0016] FIG. 2 shows the flotation chamber with anchor line. The cables to the shroud are cut at match line (A).
DETAILED DESCRIPTION OF THE INVENTION
[0017] As the water flows through front shroud ( 4 ), it's velocity and pressure increases. When the flow enters turbine housing ( 1 ), it has reached maximum velocity and pressure. It is in the area ( 2 ) that the work is being done of rotating the turbine blades. As the water passes through the rear shroud ( 3 ), its velocity and pressure is decreased continually until it merges again with the outside flow.
[0018] The draw line ( 6 ) which passes through all the purse rings ( 5 ) and is attached at one end to the front of the shroud ( 4 ) has the ability when pulled, to purse (draw together) the purse rings ( 5 ) and stop the water flow through the turbine. When the draw line ( 6 ) is released, the shroud ( 4 ) will again open, allowing water to pass through the turbine. The cable ( 7 ) attaches the front shroud ( 4 ) to the flotation chamber ( 8 ).
[0019] The scope angle adjustment ( 9 ) is where the anchor line ( 10 ) is attached to the flotation chamber ( 8 ). By adjusting the attachment point of the anchor line ( 1 ) fore or aft, the scope angle
[0020] The embodiment is designed to be pulled below the water surface by the increased amount of drag created when the turbine is operating. When the turbine is switched off or the front shroud ( 4 ) is pursed, drag will decrease and the entire embodiment will float to the surface of the water body.
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The embodiment is a venturi front shroud that can be pursed or released to decrease or increase water velocity through the housing of a turbine.
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TECHNICAL FIELD
[0001] The present invention relates to an industrial robot comprising a manipulator and control equipment where the manipulator has three arms, each arm having a linkage supporting a movable platform. The control equipment comprises drives and means including a microprocessor and software for driving and guiding the manipulator in the desired manner. To achieve the desired movement of the platform, the linkages comprise links or rods that are articulately connected between the platform and the arms. Each joint allows a movement in three degrees of freedom. The arms are fixed to stationary actuators that allow a movement in one degree of freedom. This movement comprises both rotation and translation. The task of the platform is to directly or indirectly support tools or objects for movement, measurement, processing, machining, joining, etc.
BACKGROUND ART
[0002] For movement and rotation of objects without changing the inclination of the objects, so-called SCARA-type robots are primarily used today. These robots are designed for the four degrees of freedom, x, y, z and rotation of an object around the z-axis. For manipulation of the object in the xy-plane, two series-connected arms are used that operate in the xy-plane, the axes thus being perpendicular to the xy-plane. The fact that the arms are connected in series implies that one arm supports the other arm, which in turn supports the object. To obtain a movement in the z-direction, a linear movement device is used. This device may be located either after the series-connected arms or before the series-connected arms in the serial kinematic chain of the robot. In the former case, the series-connected arms must move the drive package for the z-movement and in the latter case the drive package for the z-movement must move the series-connected arms. The drive package for rotating the object around the z-axis will always be located furthest out in the kinematic chain of the robot.
[0003] The series connection of the arms of the SCARA robot, as well as in other robots with series-connected links, implies that the robot is given a large movable mass, that the robot structure is weak, that the accuracy is limited and that large motor torques are required to make fast movements.
[0004] Several of the drawbacks that are associated with the SCARA robot are overcome by a robot that manipulates a platform with three parallel-working arms. This is referred to as a parallel kinematic structure. To obtain a rigid arm system with a large loading capacity and a low weight, the outer arms of the parallel-kinematic manipulator, nearest the manipulated platform, shall consist of six links in total, which only transfer compressive and tensile forces. A manipulator for movement of a platform in space is previously known, where the platform has the same inclination and orientation in its entire working range. The known robot has three parallel-working arms, each having its own linkage. It is known in this context that the total number of links is six and that they may be optionally distributed on the arms according to the combinations 2/2/2 or 3/2/1.
[0005] To more readily describe parallel-kinematic robots comprising linkages, some definitions of different linkages are introduced here:
[0006] Link: A link is a member that movably joins two elements and that, at each end, allows movement in three degrees of freedom. It usually consists of a rigid elongated member such as, for example, a rod that has a ball joint at each end. The link holds the elements at a definite distance from each other and absorbs only tensile or compressive forces. Thus, a link transfers no torsional movements.
[0007] Double link: A double link is a member that movably joins two elements, that at each end allows movement in three degrees of freedom, and that transfers a moment in a plane between the elements. The double link consists of a quadrangle with, for example, two links, according to the above, that form a first pair of links and the elements that form the second pair of links. In a special case, the double link is a parallelogram, in which case the two elements are forced to move in parallel with each other. Since all joints allow movement in three degrees of freedom, this implies that the double link may twisted. Thus, the double link needs help from other linkages to remain plane.
[0008] Locked double link: A locked double link is a member that movably joins two elements that, at each end, allows movement in two degrees of freedom. The locked double link consists of a double link according to the above, wherein at least one diagonal is locked. This is achieved, for example, by introducing in the quadrangle an additional link that is not parallel to any of the other links. This prevents the elements from being displaced, but still the locked double link may be twisted.
[0009] Triple link: A triple link is a member that movably joins two elements, that at each end allows movement in three degrees of freedom, and that transfers a moment in two planes between the elements. The triple link usually consists of two double links, oriented in different planes, with one common link. In a special case, the triple link comprises a space parallelogram consisting of three parallel links of equal length. Such a space parallelogram may be twisted but maintains the elements oriented in parallel planes.
[0010] Triangle: A triangle is a member that movably joins two elements and that at one end (the base) allows movement in one degree of freedom and at its other end allows movement in three degrees of freedom.
[0011] The triangle consists, for example, of a torsionally rigid member that, at its base, is journalled to a first element through an axis and at its other end is journalled to a second element by means of a ball joint. A triangle may also consist of two links according to the above, where one of the joints is common.
[0012] In the following text, an arm for a robot shall mean a linkage supported by a supporting arm. By the concept supporting arm is to be understood a torsionally rigid member that movably joins two elements together and that, at both ends, allow movement in one degree of freedom. The supporting arm consists, for example, of a tube with a fork arranged at each end through which an axle passes. In a special case, the axles are parallel whereby the elements joined by the supporting arm are allowed movement in one plane only. It should be mentioned that the movement comprises rotation as well as translation. The supporting arm may, from one element to the other, transfer both tensile and compressive forces, torsional moment and bending moment.
[0013] With the linkages defined above, the first of the known systems may be defined as a manipulator with three arms, each one consisting of a supporting arm and a double link. The second known manipulator may be defined as a manipulator with three arms wherein the first arm consists of a supporting arm and a link, the second arm of a supporting arm and a double link, and the third arm of a supporting arm and a triple link. It should be pointed out here that when designing according to the configuration 2/2/2, the axles of the supporting arms must cross each other to obtain an unambiguous orientation of the movable element.
[0014] For a fully extended parallel-kinematic robot for movement of a platform with three degrees of freedom (e.g. in directions x, y and z in a Cartesian system of coordinates), three parallel-working arms are required. If all six degrees of freedom of the platform (x, y, z and the tool orientation) are to be manipulated, six parallel-working arms are required. Each such arm comprises an upper arm and a lower arm. In several applications, a manipulation with a combination of degrees of freedom for positioning and degrees of freedom for orientation is desired. One class of such applications is interior work in narrow spaces. In that case, it is often desired to have a robot with two degrees of freedom for tool orientation and only one degree of freedom for radial positioning.
[0015] From U.S. Pat. No. 5,539,291, a parallel kinematic manipulator is previously known. A centre pillar supports a supporting arm operable around two axes. This supporting arm supports, in turn, a second supporting arm that supports a movable element. A first and a third supporting arm journalled about the same axis are connected to the movable element by means of outer arms comprising wires that, with respect to their function, may be likened to a combination of a supporting arm and a double link. The outer arms, as well as the second supporting arm, are arranged to transmit tensile and compressive forces as well as torsional moments. This entails a clumsy design of the manipulator. From the point of view of smoothness and the like, this manipulator cannot compare favourably with a corresponding manipulator where the outer arms only absorb tensile and compressive forces.
[0016] From WO98/30366, a parallel kinematic manipulator is previously known. Three arms including linkages here join together a stationary element and a movable element. Three actuators fixed to the stationary element each operate an arm. A first arm includes a supporting arm with a triple link. A second arm includes a supporting arm and a double link. A third arm includes a supporting arm and a link. The links included in these linkages only need to transmit compressive and tensile stresses, which makes them very rigid, although they are designed with small dimensions and of a light material. In addition, the joints are only subjected to a normal force from the links and the bearings may therefore be made light, stiff and accurate.
[0017] From WO99/58301, a further parallel kinematic manipulator is previously known. Also here, three arms including linkages join together a stationary element and a movable element. Three actuators fixed to the stationary element each operate an arm. All arms include a supporting arm with a double link, wherein the arms transmit compressive and tensile stresses only. This arm structure has been made possible by designing the manipulated platform as a frame structure in three dimensions instead of a platform in the form of a plane structure in two dimensions, as in the above known manipulator (WO98/30366).
[0018] Both in the case of a two-dimensional and in the case of a three-dimensional manipulated platform according to the above-referred known manipulators, the problem arises that the arm that provides the movement of the robot in the vertical direction (in the z-direction) is influenced by large forces. In the case of large movements of the other arms (in the xy-plane), this arm will be influenced not only by torsional moments but also by strong bending moments. Especially unfavourable are forces that, in the outer end of the arm, act in an axial direction. The design implies that, when the robot is extended, said arm in the vertical direction will be located obliquely between the other two arms, as well as when the robot is folded together. Because of the kinematics, said arm for the z-manipulation will be located midway between the other two arms only within a narrow radial distance from the centre of the robot. This entails the following disadvantages:
[0019] The working range is limited by the fact that the arm for z-manipulation is given an unfavourable position relative to the other arms.
[0020] The rigidity of the robot will be limited by the fact that the arm for z-manipulation places at least one articulated rod in an unfavourable direction relative to the manipulated platform.
[0021] The accuracy of the robot will be limited by the extra kinematic non-linearity created by the arm for z-manipulation.
[0022] The dynamic properties and the rapidity of the robot are limited by the fact that the arm for z-manipulation is subjected to oblique dynamic forces.
[0023] The kinematics of the robot does not automatically provide radial movement planes but a complicated mathematical compensation must be made in the control system for the curvature caused by the arm for z-manipulation.
SUMMARY OF THE INVENTION
[0024] The object of the present invention is to suggest ways and means of producing a parallel-kinematic robot that exhibits a large working range and that prevents the arms of the robot from being subjected to unfavourable forces. This is achieved by an industrial robot with a manipulator comprising a stationary element, a movable element and three arms interconnecting the elements, each arm having a supporting arm and a linkage supported by the supporting arm, the movement plane of a central arm being adapted to intersect the movable element upon all movements.
[0025] From a first aspect of the invention, the manipulator comprises a linkage that allows the movable element a movement in space, where the orientation of the element is all the time the same irrespective of position. From a second aspect of the invention, the manipulator comprises a linkage that allows the movable element a movement along a conceived cylinder where the radius is varied. From a third aspect of the invention, the manipulator comprises a linkage that allows the movable element a movement along a spheroid where the radius is varied.
[0026] The manipulator, which is common from all aspects, comprises a first supporting arm, a second supporting arm, and a third supporting arm. The second supporting arm will be referred to below also as the central supporting arm. Besides being journalled about a first axis, around which the drive system is arranged, this central supporting arm is also freely journalled about a second axis arranged substantially in a normal plane to the drive shaft. The method for imparting to the central arm only small transverse forces comprises adapting the central arm, by connections to the other arms, to adopt a position in between these.
[0027] In a first preferred embodiment, the manipulator comprises an additional supporting arm, which is journalled at the central supporting arm. The end of this additional supporting arm is joined by a first link to the first supporting arm and by a third link to the third supporting arm. In a further preferred embodiment, the additional arm comprises a triangle journalled with the base to the central supporting arm. In an additional preferred embodiment, the central supporting arm comprises a rod that is fixed to the arm and on which a sleeve is running. The rod is joined to the first and third supporting arms, respectively, by a first and third link. It should also be mentioned that the further supporting arm, the triangle or the rod may equally be arranged both between the two elements and behind the stationary element.
[0028] In a further preferred embodiment, the manipulator comprises a triangle, the base of which is journalled at the outer end of the central supporting arm and the top of which is journalled to the movable element. This embodiment presupposes that the linkages, which is supported by the other two supporting arms, comprise a double link and a triple link. In this embodiment, transverse forces are thereby allowed to influence the central arm. Since the central supporting arm is freely journalled in the direction of the transverse force, these forces will be moderate. In a special case, the movable element of the manipulator is formed elongated, all the link attachments thus being arranged on a straight line. The manipulator thus shaped is operated with five links only.
[0029] To lock all of the six degrees of freedom of the manipulated platform, a total of at least six (in a special case five) articulated rods are used. In this way, each articulated rod will only have to transmit tensile and compressive forces, which allow the articulated rods to be made very rigid, light and accurate. Articulated rods mounted on the same supporting arm, in those cases in which they are more than one, are mounted in parallel with one another and are made equally long.
[0030] The industrial robot according to the invention also comprises a control unit that handles the movements of the manipulator. The control unit comprises drives for each of the arms, power transmission, etc., and comprises a plurality of microprocessors, which are brought to operate the manipulator by means of instructions from a computer program.
BRIEF DESCRIPTION OF THE DRAWING
[0031] The invention will be explained in greater detail by means of embodiments with reference to the accompanying drawing wherein
[0032] [0032]FIG. 1 shows a known parallel-kinematic robot in which an actuator is mounted on an arm that is turned around by another manipulator and the working range and dynamic and static performance of which are therefore considerably limited,
[0033] [0033]FIGS. 2A and 2B illustrate the kinematic problems that arise when the robot according to FIG. 1 is used,
[0034] [0034]FIG. 3 shows a manipulator according to the invention with a mechanism that centers the central supporting arm of the manipulator between two other supporting arms, thus solving the kinematic problems associated with the embodiment of FIGS. 2A and 2B,
[0035] [0035]FIGS. 4A and 4B show two advantageous embodiments of the manipulator according to the invention,
[0036] [0036]FIG. 5 shows a further advantageous embodiment of the manipulator according to the invention, where the mechanism is placed in front of the centre of the robot,
[0037] [0037]FIG. 6 shows an alternative advantageous embodiment of the manipulator, in which the already existing structure in the manipulator is utilized for forming a triangle,
[0038] [0038]FIG. 7 shows an additional advantageous embodiment of a manipulator according to the invention, wherein the centring mechanism comprises a locked double link formed from links in combination with existing links, whereby the normal to the platform manipulated by the robot will always be directed radially outwards from the centre of the robot, and
[0039] [0039]FIG. 8 shows an advantageous embodiment of the manipulator according to FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0040] [0040]FIG. 1 shows a parallel-kinematic robot, which is a development of the known structures disclosed in, inter alia, U.S. Pat. No. 5,539,291. The robot is mounted on a foot 1 A, on which a column 1 B is secured. On this column there is arranged a first actuator 2 that pivots a first supporting arm 5 around a first axis, and a second actuator 3 that pivots a second supporting arm 6 A around a second axis. Both axes are parallel to each other, whereby the two supporting arms are each pivoting in respective horizontal planes shown in the figure. The actuators 1 and 2 are of the rotary type with coinciding vertical axes of rotation. On the arm 6 A, an element 1 C is secured by means of a holder 1 D, and on this element a third actuator 4 is mounted. This causes the actuator 4 to be rotated by the actuator 3 around the vertical axis of rotation of the actuator 3 . The third actuator 4 pivots a third supporting arm 7 A in a vertical plane shown in the figure. The third axis is thus oriented substantially across the other two axes. When the actuator 3 pivots the arm 6 A, the arm 7 A will thus accompany the movement of the arm 6 A and the angle between the projection of the arm 7 A (in a horizontal plane extending through the arm 6 A) and the arm 6 A will be constant.
[0041] On the arm 5 A, an articulated-rod arrangement consisting of three articulated rods 8 A, 8 B and 8 C in a triangular configuration is mounted with the aid of joints 11 a , 11 B and 11 C, respectively. At their other ends, the articulated rods 8 A, 8 B and 8 C are mounted with the aid of the joints 12 A, 12 B and 12 C, respectively, on the platform 17 that is to be manipulated by the robot. The articulated rods 8 A, 8 B and 8 C have equal lengths and are mounted in parallel. This arrangement forms a triple link. The platform 17 is maintained parallel to the surface that is put up by the arm 5 A and the vertical rod 5 B, which is fixedly mounted on the arm 5 A.
[0042] On the arm 6 A, the vertical rod 6 B is mounted in a corresponding manner, and the arm 6 A is connected to the platform 17 via the articulated-rod arrangement consisting of the articulated rods 9 A and 9 B. The articulated rods 9 A and 9 B are at one of their ends connected to the arm 6 A and the rod 6 B through the joints 13 A and 13 B, respectively, and at their other end connected to the platform 17 through the joints 14 A and 14 B. The articulated rods 9 A and 9 B are mutually parallel and have equal lengths. This arrangement forms a double link. The platform 17 is maintained parallel to the rod 13 A. In this embodiment, the articulated-rod arrangement between the third supporting arm 7 A and the platform 17 consists of only one link, which is articulately connected to the arm 7 A through the joint 15 A and the platform 17 through the joint 16 A.
[0043] All the joints may have two or three degrees of freedom. In order not to obtain inherent stresses in the structure, for each articulated rod at least one end should have a joint with three degrees of freedom.
[0044] When the actuators 2 and 3 cause the arms 5 A and 6 A to pivot relative to each other, the platform 17 will be moved substantially radially outwards/inwards away from/towards the column 1 B and when the actuators 2 and 3 are run synchronously in the same direction, the arms 5 A and 6 A will pivot in the same direction with a constant mutual angle and the platform 17 will be pivoted along a circular orbit with the column 1 B in the centre. When the actuator 4 pivots the arm 7 A, the platform 17 will be moved substantially upwards/downwards, and all in all a symmetrical toroidal working range around the column 1 B is obtained, which may be compared with the working range of a conventional, so-called SCARA robot.
[0045] [0045]FIG. 2 is a schematic picture of the robot in FIG. 1 seen from above, partly in a position where the platform 17 is near the column 1 B (FIG. 2A), and partly where the platform 17 is far away from the column 1 B (FIG. 2B). The arm 5 ( 5 A and 5 B in FIG. 1) is connected to the platform 17 via the articulated-rod arrangement 8 ( 8 A, 8 B, 8 C). On the articulated-rod arrangement 8 , the joints 11 ( 11 A, 11 B and 11 C) are positioned at one end and the joints 12 ( 12 A, 12 B and 12 C) are positioned at the other end. In a corresponding manner, the arm 6 ( 6 A, 6 B) is connected to the platform 17 via the joints 13 ( 13 A, 13 B), the articulated rods 9 ( 9 A and 9 B) and the joints 14 ( 14 A, 14 B). Finally, the arm 7 is connected to the platform 17 via the joint 15 , the articulated rod 10 and the joint 16 .
[0046] Because of the parallel articulated rods 8 ( 8 B, 8 C), the platform 17 will always be parallel to the arm 5 ( 5 A), and in FIG. 2A, therefore, the platform 17 is angled to the left and in FIG. 2B to the right. Since the actuator 4 (see FIG. 1) is mounted on the arm 6 a , the angle between the arm 7 and the arm 6 , viewed from above as in FIG. 6, will always be constant. This means that the arm 7 in FIG. 2A will be situated nearer the arm 6 that the arm 5 and that the arm 7 in FIG. 2B will be situated nearer the arm 5 than the arm 6 . From this follows, in turn, that the working range of the robot cannot be utilized in full and that different oblique loads are imparted to the arm 7 in dependence on where in the working range the platform 17 is situated. To eliminate these problems, a robot structure is required that will ensure that the arm 7 will always be situated midway between the arms 5 and 6 .
[0047] [0047]FIG. 3 shows a mechanism for forcing the arm 7 to always be situated midway between the arms 5 and 6 (viewed in a projection on the horizontal plane). The only difference between the robot in FIG. 3 and in FIG. 1 is that the coupling 1 D in FIG. 1 has been replaced by a bearing 18 . This bearing enables the element 1 C of the central column to rotate freely relative to the element 1 B of the central column and the actuators 2 and 3 . What is now required is an extra mechanism on the robot that ensures that the arm 7 A is always situated midway between the arms 5 A and 6 A or at least situated in a position with a constant angular ratio between the arms 5 A and 6 A. The simplest way of doing this is, of course, to install a fourth motor that rotates in the element 1 C relative to the element 1 B, but this results in a robot which is both more expensive and heavier. Instead, in FIG. 3, an extra articulated-rod mechanism ( 19 - 26 ) has been introduced behind the robot.
[0048] The swinging arm 19 is mounted on an axle 20 on the element 1 C and is capable of pivoting in a vertical plane behind the robot. At the other end, the pivoting arm 19 is mounted via the joints 23 and 24 (the joint 24 is located behind the arm 19 in the figure) on the articulated rods 21 and 22 , respectively. These articulated rods are then mounted on the arms 6 A and 5 A, respectively, by means of the joints 25 and 26 , respectively. When the arms 5 A and 6 A move relative to each other, the articulated rods 21 and 22 will pivot the arm 19 up/down in a plane determined by the ratio between the articulated rods 21 and 22 . Since this ratio is constant, said plane will end up with a constant ratio between the arms 5 A and 6 A, and the arm 7 A will always pivot with this ratio between the arms 5 A and 6 A. If the ratio is chosen to be 1/1 (links 21 and 22 being of the same length and joints 25 and 26 lying in the same horizontal plane, which they do not in the figure), the arm 7 A will always be located midway between the arms 5 A and 6 A.
[0049] The joints 23 , 24 , 25 and 26 must all have at least two degrees of freedom each. The axle 20 gives the arm 19 one degree of freedom relative to the element 1 C.
[0050] [0050]FIG. 4 shows a robot viewed from behind to more clearly illustrate the mechanism for centring the arm 7 A. The parallel-kinematic robot itself differs, from the point of view of structure, from the one in FIG. 1 as far as the platform 17 is concerned. The platform in FIG. 4 consists of an axle 17 with a cross-beam 17 B. On the axle 17 , the joints 16 A, 12 A, 14 A, 12 B and 14 A are mounted along a common symmetry line. On the cross-beam 17 B, the joint 12 C is mounted. The joints 12 A, 12 B and 12 C connect the platform 17 / 17 B to the articulated rods 8 A, 8 B and 8 C, respectively, and these articulated rods are then mounted on the arm parts 5 B and 5 C by means of the joints 15 A, 15 B and 15 C, respectively. The arm parts 15 B and 15 C are secured to the arm 5 A, which is driven round by the actuator 2 , which in this figure is mounted above the motor 3 on the column 1 B. The actuator 3 drives the arm 6 A, on which the articulated rods 9 A and 9 B are mounted via the joints 13 A and 13 B, respectively. At their other ends, the articulated rods are mounted on the platform axle 17 by way of the joints 14 A and 14 B, respectively. The actuator 4 is mounted on the element 1 C, which is capable of being rotated relative to the column 1 B through the bearing 18 , which has its axis of rotation coinciding with the axes of rotation of the actuators 2 and 3 . The actuator 4 is connected to the platform 17 via the arm 7 A, the arm part 7 B, the joint 15 A, the articulated rod 10 A and the joint 16 A.
[0051] The centring of the arm 7 A between the arms 5 A and 6 A is here carried out with the aid of the mechanism 19 - 26 . This mechanism has been made more rigid than that shown in FIG. 3 by mounting double pivoting arms 19 A and 19 B on the axle 20 on the platform part 1 C. When the arms 5 A and 6 A are moving relative to each other, the articulated rods 21 and 22 will, via the common joint 23 , pivot the arm pair 19 A and 19 B upwards/downwards around the axle 20 . If the articulated rods 21 and 22 are of equal length and if the joints 25 and 26 are mounted in the same horizontal plane, then the arm 7 A will be guided to end up midway between the arms 5 A and 6 A. In FIG. 4B, a variant of the centring mechanism in FIG. 4A is shown. Here, the joint 23 has been replaced by the two joints 23 and 24 , which is mounted on a system of pivoting arms that, besides the arms 19 A and 19 B, consists of a cross-beam 19 C. This design provides a somewhat lower rigidity than the design of FIG. 4A but provides a simpler joint design.
[0052] For both FIGS. 4A and 4B, the joints 23 - 26 have at least two degrees of freedom each.
[0053] [0053]FIG. 5 shows the same robot as in FIG. 3 but with the mechanism for centring of the arm 7 A in front of the column 1 B instead of behind as in FIGS. 3 and 4. In the same way as in FIG. 3, the joint 25 is mounted on the arm 6 A and the joint 26 on the arm SA. However, the joints 20 A and 20 B are now not directly mounted via an axle on the column segment 1 C but are now mounted on a cross-beam 7 B on the arm 7 A. The links 21 and 22 are mounted at one end on the joints 25 and 26 , respectively, and at their other ends on the common joint 23 . The links 19 A and 19 B are also mounted on the common joint 23 and at their other ends on the joints 20 A and 20 B. The common joint 23 may, of course, be divided into two or more joints in the same way as in FIG. 4B. All the joints of this centring mechanism have at least two degrees of freedom.
[0054] [0054]FIG. 6 shows the same robot as in FIG. 3 but now with a different mechanism for centring the arm 7 A between the arms 5 A and 6 A. This mechanism is based on the fact that the bearing 18 introduces another degree of freedom of the assembled robot structure and that this provides a possibility, by redundant locking of degrees of freedom of the platform 17 , of locking the new degree of freedom arisen through the bearing 18 between the column 1 B and the element 1 C. In the figure, the redundant locking is performed with the aid of the seventh articulated rod 10 B. This articulated rod is, at one end, mounted via the joint 16 A on the platform 17 and, at its other end, via the joint 15 B on the cross-beam 7 B, which is secured to the arm 7 A. In the figure, the articulated rod 10 B shares the same joint with the articulated rod 10 A, which is necessary for the platform 17 to be able to rotate around a vertical axis of rotation since it is to be maintained parallel to the arm 5 A through the articulated rods 8 B and 8 C. At its upper end the articulated rod 10 A is mounted by means of the joint 15 A in the cross-beam 7 B. The joints 15 A and 15 B may have one, two or three degrees of freedom and the joint 16 A must have at least two degrees of freedom. In the case where the joints 15 A and 15 B have only one degree of freedom, the axes of rotation of these must be coinciding. It is to be preferred that all the joints ( 15 A, 15 B and 16 A) have three degrees of freedom to prevent mechanical stresses from building up in the articulated rods and the joints.
[0055] [0055]FIG. 7 shows a variant of the robot in FIG. 6. In the same way as in FIG. 6, seven articulated rods are used between the three arms ( 5 A, 6 A and 7 A) of the robot and the platform 17 , but now a different distribution of articulated rods between the arms has been made. Thus, the arms 5 A and 6 A are connected to the platform 17 through two articulated rods each ( 8 B 8 C and 9 A, 9 B, respectively). To obtain a total of seven articulated rods between the platform and the arm system, the arm 7 A must now be connected to the platform 17 by three articulated rods. In order that all the six degrees of freedom of the platform plus the degree of freedom due to the bearing 18 shall now be locked, a maximum of two of these three articulated rods ( 10 A, 10 B, 10 C) must be parallel. Thus, in FIG. 7 the articulated rods 10 A and 10 C are parallel whereas the articulated rod 10 B is diagonally mounted between the articulated rods 10 A and 10 C. The three articulated rods 10 A, 10 B and 10 C will require that a line through the joints 16 A- 16 C be parallel to a line through the joints 15 A- 15 C, and for this to be possible, the arm 5 A has been provided with a parallelogram mechanism. This mechanism adjusts the beam 34 B such that this is always parallel to the beam 7 B, whereby the platform 17 will no longer follow the orientation of the arm 5 A but will always have the same constant orientation relative to the arm 7 A that is centred midway between the arms 5 A and 6 A. The parallelogram mechanism comprises the arm 30 , which is secured to the element 1 C, the free flexible axle 31 , the parallelogram arm 33 that is parallel to the arm 5 A, the free flexible axles 35 and 36 , and the L-formed beam 34 A- 34 B. When the arm 5 A is rotated relative to the element 1 C, the beam part 34 B of the L-formed beam 34 A- 34 B will be pivoted by the parallelogram arm 33 such that the beam part 34 A is maintained parallel to the beam 30 that is secured to the column element 1 C, which, with a suitable choice of the angle between the beam parts 34 A and 34 B, means that the beam part 34 B is maintained parallel to the beam 7 B. It should be mentioned that the perspective drawing in the figure is not satisfactory, but in the figure a line through the joints 11 B and 11 C shall be parallel to a line through the joints 12 B and 12 C and parallel to a line through the joints 16 A, 16 B and 16 C as well as parallel to a line through the joints 15 A, 15 B and 15 C. It should also be pointed out that the mechanics between the beam 30 and the parallelogram arm 33 is only schematically drawn. There should actually be a frame structure here in order to obtain a rigid joint around the axle 31 .
[0056] [0056]FIG. 8, finally, shows a variant of the structure in FIG. 7. With the introduction of the bearing 18 , articulated rods are required between the arm system and the platform 7 . In FIG. 7, these articulated rods are distributed among the arms 5 A, 6 A and 7 A as 2/2/3. However, there are also other functioning distributions, as, for example, 3/2/2 and 3/1/3. The case of 3/1/3 is shown in FIG. 8. The only thing that has been added here relative to FIG. 7 is that the beam angle 34 A- 34 B has been supplemented with the vertical beam 34 C, on which the articulated rod 8 A has been mounted and that the articulated rod 9 A has been removed. In the case of 3/2/2, the articulated rod 8 A according to FIG. 8 and the link 9 A according to FIG. 7 are used whereas the link 10 C is suitably removed from the arm 7 A.
[0057] The joints 15 A, 15 B, 15 C, 16 A, 16 B and 16 C in both FIG. 7 and FIG. 8 may have either one, two or three degrees of freedom. In the case of one degree of freedom, the axes of rotation of the joints 15 A, 15 B and 15 C shall coincide, and likewise the axes of rotation of the joints 16 A, 16 B and 16 C shall coincide.
[0058] The articulated rods 8 A, 8 B, 8 C, 9 A, 9 B, 10 A, 10 B are mounted on the platform 17 by means of the joints 12 A, 12 B, 12 C, 14 A, 14 B, 16 A. In a corresponding manner, the articulated rods 8 A, 8 B, 8 C, 9 A, 9 B, 10 A, 10 B are mounted by means of joints 11 A, 11 B, 11 C, 13 A, 13 B, 15 A on the three pivoting arms 5 A, 6 A, 7 A in order to form kinematic chains. Thus, a first kinematic chain is obtained consisting of a first element 1 C, on which the third pivoting arm 7 A is mounted, the third pivoting arm itself 7 A and the articulated rods 10 A, 10 B connected to the third pivoting arm 7 A. A second kinematic chain is defined by a second element 1 B, on which the first two pivoting arms 5 A, 6 A are mounted, one 5 A of the first two pivoting arms 5 A, 6 A, the articulately rods 8 A, 8 B, 8 C connected to said one 5 A of the first two pivoting arms, the manipulated platform 17 , the articulated rods 9 A, 9 B connected to the other 6 A of the said first two pivoting arms mounted on said element 1 B, and the other 6 A of said first two pivoting arms 5 A, 6 A.
[0059] The articulated rods mounted on the same pivoting arm are mounted, in those cases where there are more than one, parallel to one another and are made with equal lengths. The joints 11 A, 11 B, 11 C, 12 A, 12 B, 12 C, 13 A, 13 B, 14 A, 14 B of the articulated rods 8 A, 8 B, 8 C, 9 A, 9 B that are included in the second kinematic chain have two or three degrees of freedom whereas the joints 15 A, 15 B, 15 C, 16 A, 16 B, 16 C of the articulated rods 10 A, 10 B, 10 C that are included in the first kinematic chain may also have one degree of freedom.
[0060] To obtain a robot with a large working range and with good dynamic properties, the axes of rotation, around which the above-mentioned first two pivoting arms 5 A, 6 A are pivoting, must not be perpendicular to each other and the best performance is obtained if these axes of rotation are parallel and preferably coinciding. For the third pivoting arm 7 A, its axis of rotation must not be parallel to any of the axes of rotation of the first two pivoting arms 5 A, 6 A, and the best performance is obtained if the axis of rotation of the third pivoting arm 7 A is perpendicular to the axes of rotation of both of the first two pivoting arms 5 A, 6 A.
[0061] The invention comprises a robot in which the above-mentioned first element 1 C is connected to the above-mentioned second element 1 B via a bearing 18 such that the first element 1 C may be freely rotated relative to the second element 1 B. This implies that the third pivoting arm 7 A, which is mounted via a joint or a rotating actuator 4 on the first element 1 C, may pivot in different directions relative to the second element 1 B. With the introduction of said bearing 18 , an extra degree of freedom has been introduced between said first kinematic chain and said second kinematic chain, which may be utilized for guiding the first kinematic chain such that a favourable position of the components thereof 1 C, 4 , 7 A, 7 B, 15 A, 10 A is obtained relative to the components 5 A, 5 B, 5 C, 11 A, 11 B, 11 C, 8 A, 8 B, 8 C, 12 A, 12 B, 12 C, 17 , 17 A, 14 A, 14 B, 9 A, 9 B, 13 A, 13 B, 6 A, 6 B in the second kinematic chain when said platform 17 is manipulated by the robot in its working range.
[0062] The inventive concept comprises guiding the above-mentioned kinematic chains relative to each other by introducing a bridge between these kinematic chains. This bridge comprises one or more extra articulated rods 10 B, 10 C, 21 , 22 connected to joints 15 B, 16 A, 15 C, 16 C, 23 , 24 , 25 , 26 directly or via pivoting arms 19 , 19 A, 19 B and/or other extra articulated rods 19 A, 19 B. Since said kinematic chains are separated by the previously mentioned bearing 18 , said bridge will lock the degree of freedom of rotation provided by said bearing 18 .
[0063] The inventive concept also comprises mounting said bearing 18 such that its axis of rotation is not perpendicular to the axes of rotation of said first two pivoting arms 5 A, 6 A and not parallel to the axis of rotation of said third pivoting arm 7 A. To obtain the largest possible working range and optimum dynamic properties of the robot, said bearing 18 is mounted such that its axis of rotation becomes parallel to and preferably coinciding with the axes of rotation of said first two pivoting arms 5 A, 6 A and at the same time perpendicular to the axis of rotation of said third pivoting arm 7 A.
[0064] The inventive concept also comprises mounting an extra articulated rod 10 B between the manipulated platform 17 and the third pivoting arm 7 A to obtain said bridge that is to lock the degree of freedom of rotation provided by said bearing 18 . This extra articulated rod is mounted at an angle relative to the already existing articulated rod 10 A between the platform 17 and the third pivoting arm 7 A. At one end the extra articulated rod 10 B is mounted on the platform 17 by a common joint 16 A with the already existing articulated rod 10 A and at its other end the extra articulated rod 10 B is mounted on a beam 7 B some distance away from the existing articulated rod 10 A. The beam 7 B is secured to the third pivoting arm 7 A and is mounted so as not to become parallel to the third pivoting arm 7 A but preferably perpendicular thereto. In that way, a movement of the platform 17 in the lateral direction will force the third pivoting arm and the first element 1 C to rotate on said bearing 18 and thus to accompany the movement of the platform in the lateral direction, which, in turn, means that the third pivoting arm will be situated in the centre of the working range between the first two pivoting arms 5 A, 6 A. The extra articulated rod 10 B and the existing articulated rod must have a common rod 16 A towards the platform 17 to allow this to rotate when being manipulated in the radial direction relative to the centre of the robot.
[0065] The inventive concept also comprises using a kinematic bridge that does not need a common joint 16 A towards the platform 17 . To this end, a parallelogram mechanism 30 , 31 , 33 , 35 , 34 A, 36 is introduced in one of the first two pivoting arms. By connecting this parallelogram mechanism between the first element 1 C and the articulated rods 8 A, 8 B, 8 C belonging to the current one 5 A of the first two pivoting arms, the platform 17 will always be capable of being maintained parallel to a cross-beam 7 B to the third pivoting arm 7 A. This makes it possible to use two or more articulated rods between the manipulated platform 17 and the cross-beam 7 B to the third pivoting arm 7 A without a common joint being required at the platform 17 . For example, when using two articulated rods when connecting the third pivoting arm 7 A to the platform 17 , a triangular configuration of the articulated rods, with its base on the platform 17 , may be used. Further, when two articulated rods are used, a parallelepipedic configuration may be used. When two articulated rods are used between the third pivoting arm 7 A and the platform 17 , the first two pivoting arms 5 A, 6 A will need together five articulated rods to the platform 17 , in which case the distribution between the pivoting arms is three for one of the pivoting arms and two for the other. If instead three articulated rods 10 A, 10 B, 10 C are mounted between the cross-beam 7 B of the third pivoting arm 7 A and the platform 17 , only four articulated rods altogether will be required for the first two pivoting arms 5 A, 6 A, and these may then be distributed in two different ways, either two articulated rods each for the first two pivoting arms 5 A, 6 A or three articulated rods for one and one articulated rod for the other of the first two pivoting arms. When three articulated rods are used between the third pivoting arm and the platform, all the three articulated rods may not be mounted in parallel but at least one articulated 10 B must be mounted at an angle relative to the other articulated rods 10 A, 10 C. In fact, none of these articulated rods 10 A, 10 B, 10 C need to be parallel. On the other hand, all the joints 16 A, 16 B, 16 C of the articulated rods towards the platform must be situated along a line that is parallel to a line through the joints 15 A, 15 B, 15 C of the articulated rods towards said cross-beam 7 B. These lines should, in addition, be parallel to the axis of rotation of the third pivoting arm 7 A. It should be pointed out that the joints 15 A, 15 B, 15 C, 16 A, 16 B, 16 C may have one, two or three degrees of freedom, and in the case of one degree of freedom all the joints at the same end of the articulated rods shall have coinciding axes of rotation. Preferable is to have three degrees of freedom at one end of the articulated rods and two or three degrees of freedom at the other end of the articulated rods in order not to build mechanical stresses into the articulated rods and the rest of the robot structure. For an optimum design, there should be no redundancy as far as locking of degrees of freedom in the previously mentioned kinematic chains is concerned.
[0066] The inventive concept comprises supplementing the extra articulated rods 21 , 22 by extra pivoting arms 19 , 19 A, 19 B and/or additional extra articulated rods 19 A, 19 B. The pivoting arms and the additional extra articulated rods are connected either to the above-mentioned first element 1 C or to the third pivoting arm 7 A. The extra pivoting arm 19 is suitably mounted on the other element 1 C via a joint with one degree of freedom so that the axis of rotation of the extra pivoting arm 19 is essentially parallel to the axis of rotation of the third pivoting arm 7 A. The additional extra articulated rods 19 A, 19 B are mounted on a cross-beam, either on the third pivoting arm 7 A or on the second element 1 C. One 21 of the extra articulated rods 21 , 22 is mounted at one end via a joint 25 with two degrees of freedom on one 6 A of the first two pivoting arms and at its other end via a joint 23 with two degrees of freedom on said pivoting arms and/or additional articulated rods. The other 22 of the extra articulated rods 21 , 22 is mounted at one end via a joint 26 with two degrees of freedom on the other 5 A of the first two pivoting arms and at its other end via a joint 24 with two degrees of freedom on said pivoting arms and/or additional articulated rods. In this way, said first kinematic chain is connected to said second kinematic chain and the extra degree of freedom through said bearing 18 is locked. This locking may easily be made such that the third pivoting arm 7 A will always be situated midway between the first two pivoting arms 5 A, 6 A.
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An industrial robot for movement of an object in space comprising a stationary platform, a movable platform adapted for supporting the object, and a first, a second and a third arm to which the platforms are joined. The first arm comprises a first actuator, a first supporting arm influenced by the first actuator and rotatable around a first axis, and a first linkage. The second arm comprises a second actuator, a second supporting arm influenced by the second actuator and rotatable around a second axis, and a second linkage. The third arm comprises a third actuator, a third supporting arm influenced by the third actuator and rotatable around a third axis, and a third linkage. The second supporting arm is freely mounted around a cross-beam that is arranged at right angles to the second axis.
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TECHNICAL FIELD
[0001] This invention relates to a method for determining phase-corrected amplitudes in a multiple echoes imaging experiment, wherein a Fast Fourier Transform FFT reconstruction is applied to the signals generated by a CPMG (Carr-Purcell-Meiboom-Gill) sequence.
BACKGROUND OF THE INVENTION
[0002] In research studies or in clinical investigations, images are used not only for evidencing the inner structures of the body but also for quantifying the available NMR (nuclear magnetic resonance) parameters, like T1, T2 or the apparent diffusion coefficient, D (known as proton density). T1, “spin-lattice” relaxation parameter, is by definition, the component of relaxation which occurs in the direction of the ambient magnetic field. T2, “spin-spin” relaxation parameter, is by definition, the component of true relaxation to equilibrium that occurs perpendicular to the ambient magnetic field. Recently, sodium T2 evolution on the treatment time-course of ADC (apparent diffusion coefficient) changes in targeted tissues are more and more considered as possible early apoptosis markers, hence important NMR parameters to be taken into consideration in research or in clinical treatment. Alkali ions, like sodium and potassium are considered to deliver important biological information whenever cellular metabolic processes are occurring, like apoptosis or necrosis. Unfortunately, 23 Na imaging, as well as other biological interesting nuclei, suffers from inherently low sensitivity that makes often the accurate quantifying difficult.
[0003] In these conditions it becomes of a major importance the correct determination of the relaxation time constants characteristic for targeted tissues, determined from a Region Of Interest (ROI) specified on the reconstructed image.
[0004] The great majority of reconstruction methods implemented on the imaging machines are using the absolute amplitude (modulus) in order to obtain the final image. This method uses the pair of images representing the real and imaginary components of the FFT transform to calculate the magnitude of each corresponding complex pair. If the real and imaginary pairs are given by Re=A r +ε r and Im=A i +ε i , (where A r and A i are the real and imaginary components of the signal, while ε r and ε i are the real and imaginary components of the noise), it is obvious that calculating the absolute value, given by M=√{square root over (Re 2 +Im 2 )}, will place every point in the reconstruction grid upon a certain positive value, given by the rectified noise level.
[0005] The presence of the positive level given by the noise absolute value is affecting the accurate determinations for the NMR relaxation parameters such as T 1 , T 2 or for D as well as any result of pixels algebra. This effect is even more important for poor signal to noise ratio (SNR) images, like sodium images, affecting the quantitative information they can produce. Nevertheless, even in the case of high SNR ratio proton images, multi-exponential relaxation may be totally covered up or extremely biased by the positive noise level.
[0006] The need to quantitatively determine the relaxation time constants, especially from non-exponential decays, leads to some mathematical manipulations in order to extract more accurately the transformed signal amplitudes.
[0007] The use of power magnitude values is re-creating a Gaussian quality for the noise by subtracting the average noise level. However, this power routine is only valid for mono-exponential relaxation decays, while most of the biological samples are heterogeneous and thus non-exponential.
[0008] Another way to avoid the undesired biased noise produced by magnitude calculation is to phase-correct the images. In the prior art, an attempt to obtain phase-corrected images was done by Louise van der Weerd, Frank J. Vergeldt, P. Adrie de Jager, Henk Van As, “Evaluation of Algorithms for Analysis of NMR Relaxation Decay Curves.”; Magnetic Resonance Imaging 18 (2000) 1151-1157. Their algorithm is based on the phase calculation of every pixel but using only the first and second echo images. The resulting correction is further applied to all subsequent echoes in the sequence. The first two echoes are thus becoming magnitude images while the rest of echo images are real, phase corrected ones. This method is based on the assumption that the first two points in the relaxation decay are less affected by the noise bias and thus, the phase corrected amplitude may be approximated by the absolute value. Nevertheless, when extracting the decay curve from the whole echoes train, a small bias is still introduced by using only the first two points, characterised by the highest SNR values. This imperfection is increasing more for poor signal to noise images.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is a simple and fast algorithm for obtaining real-phased images in a multiple echoes Magnetic resonance imaging (MRI) experiment.
[0010] Another object of the present invention is to keep the relaxation decay unperturbed by the phasing process, whatever the level of noise.
[0011] Another object of the present invention is a new method which is valid for multi-exponential decay curves.
[0012] At least one of the above-mentioned objects is achieved with a method according to the present invention for determining phase-corrected amplitudes in a multiple echoes imaging experiment, wherein a Fast Fourier Transform FFT reconstruction is applied to the signals generated by a CPMG sequence. Said signals correspond to echo images. The present invention uses a pixel-by-pixel phase correction. One ordinary skilled in the art knows that echo images consist of an evolution of an image according to the time. Thus, the amplitude of a same pixel, through the echo images, describes a decay curve. According to the present invention, for each pixel, said pixel being the same through the echo images, the method comprising the steps of:
[0013] plotting the complex amplitudes of at least two echo images in a complex plane,
[0014] defining a linear fit from the plot,
[0015] determining a rotation angle alpha (α) which is the angle between said linear fit and the real axis of the complex plane,
[0016] determining the rotation angle α min which is an optimization of the rotation angle α by minimizing the sum of the squared imaginary components of the amplitudes,
[0017] performing a rotation for amplitudes of all echo images with the rotation angle α min in order to determine the phase-corrected amplitudes.
[0018] As a matter of fact, one ordinary skilled in the art knows that the amplitude is not only affected to a pixel but rather to a voxel. The pixel representation is commonly used in the technical domain of the invention. The rotation angle α is the phase of the magnetization created in the considered voxel.
[0019] In accordance with the present invention, the linear fit can be a straight line obtained by linear regression.
[0020] With the present invention, the phase correction is achieved by rotating all the FFT coefficients in the complex plane, such as all information is transferred to the real component while the imaginary one tends to the noise level.
[0021] Contrary to the Weerd et al document, the present invention maximises all real components of amplitudes. This is a simple and fast method obtaining real-phased images, enabling an accurate determination of T2 constants on an arbitrary ROI of an image. Phased-corrected amplitudes on single pixel may add correctly, without biasing the result, in order to improve the S/N of the decay to be analysed. Moreover, an improved contrast for the phase corrected images as compared to the module images has been observed.
[0022] The method according to the invention is sufficiently robust to function for a small number of echoes. However, for some experiences, the step of plotting the amplitudes may consist of plotting the amplitudes of at least six echo images in the complex plane. For some experiences in which the decay curve has to be fit with high precision, at least eight echo images may be used to plot the amplitudes in the complex plane.
[0023] However, the step of plotting the amplitudes preferably consists of plotting the amplitudes of all the echo images in the complex plane. In fact, bigger is the number of echo images used, bigger is the precision. With the method of the present invention, the noise concerning the CPMG sequence is not modified and the shape of the decay curve is not modified. Thus, it is possible to precisely fit the decay curve concerning a pixel in order to accurately determine relaxometry parameters. On the contrary, Weerd describes a method in which the shape of the decay curve is modified: indeed the first and second echo images in Weerd are magnitude images and an angle obtained from said first and second echo image is applied to the rest of the echo images.
[0024] The present invention is notably remarkable by the fact that it corrects the phase of the entire image, by phasing each pixel separately, using all the echo images available in the sequence. More, the amplitude values used for creating the relaxation decays are not biased for any point while the Gaussian characteristic of the noise is kept. The procedure allows both the accurate T2 determination for any ROI defined on an image obtained by a multiple echoes experiment, like MSME, for example, and correct image algebra, if required.
[0025] Moreover, the use of all echo images together with the minimizing step provides the method of the invention with robustness and stability independently of the SNR.
[0026] The method of the present invention is well adapted for spin echo sequence where all echoes corresponding to a given pixel have the same phase.
[0027] Advantageously, the Golden Search routine can be used to minimize the sum of the squared imaginary components of the amplitudes.
[0028] In accordance with the present invention the phase-corrected amplitudes are fitted by using a fitting algorithm. For example, said fitting algorithm is the Singular Value Decomposition (SVD) method.
[0029] In accordance with the present invention, the real components of the phase-corrected amplitudes are used to reconstruct a real image and the imaginary components of the phase-corrected amplitudes are used to reconstruct an imaginary image. The real phase-corrected images have the advantage of preserving the same noise characteristics as the original acquired signals corresponding to the CPMG sequence.
[0030] Advantageously, at least one of NMR parameters T1, T2 and D, is determined from said phase-corrected amplitudes.
[0031] According to another aspect of the invention, it is proposed an imaging machine wherein images are determined from said phase-corrected amplitudes.
[0032] These and many other features and advantages of the invention will become more apparent from the following detailed description of the preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0033] FIGS. 1 a - 1 c show raw data for a sodium image reconstructed in complex mode ( 1 a , 1 b ) and an absolute value mode ( 1 c ) according to the prior art;
[0034] FIGS. 2 a - 2 d show Singular Value Decomposition of a decay signal in module, without ( 2 a , 2 b ) and with ( 2 c , 2 d ) base line correction according to the prior art;
[0035] FIGS. 2 e and 2 f show Singular Value Decomposition of a decay signal obtained after a phase correction procedure according to the present invention;
[0036] FIG. 3 is a flow chart of an algorithm according to the present invention;
[0037] FIGS. 4 a and 4 b illustrate experimental data points of one pixel represented in the complex plane and as a function of time, before ( 4 a ) and after ( 4 b ) phase correction according to the present invention; and
[0038] FIGS. 5 a - 5 d illustrate raw data for a sodium image after phasing procedure ( 5 a and 5 b ), and example of reconstructed corresponding images ( 5 c and 5 d ).
DETAILED DESCRIPTION
[0039] Although the invention is not limited thereto, one now will describe a phase correction routine applied to sodium images, characterised by rather poor SNR values, in ghost samples as well as in vivo mouse liver. The exponential decays thus obtained were fitted using the Singular Value Decomposition method in order to obtain objective fitting parameters. However, the phasing method proposed is obviously completely independent of the fitting algorithm, any other fitting method being suited as well.
[0040] Now will be described material used to experiment the method according to the present invention. The general purpose is to determine imaging data from a CPMG multi-slice multi-echo (MSME) sequence. The CPMG sequence used consists of a spin echo pulse sequence comprising a 90° radio frequency pulse followed by an echo train induced by successive 180° pulses and is useful for measuring T 2 weighted images.
[0041] In vivo sodium liver MR (magnetic resonance) images, as well as 23 Na ghost images were recorded using a double tuned quadrature birdcage resonating at 53 MHz for sodium and 200 MHz for proton. The probe is linear at proton frequency, being needed for localisation purposes only. The sodium images were acquired using a 8 to 32 echoes MSME pulse sequence at 4.7 T. The ghost sample contained two regions characterised by different Na ions mobility due to two different agarose concentrations (bound Na ions at 1% agarose and more freely moving ions at 0.15% agarose concentration). The different motional sodium compartments are characterised by different spin-spin relaxation times, being an ideal test for the correctness of the phase correction method. The sodium concentration in both compartments is 75 mM, corresponding to an average sodium concentration internal in living systems. In vivo sodium images were done on tumoral mice liver. The experimental conditions were: FOV=68 mm, TE=6.035 ms, Slice thickness=6 mm, Spectral width=25 kHz, reconstruction matrix=64×64.
[0042] All the images were reconstructed using Paravision® 3.02, in absolute value, real and imaginary modes.
[0043] The best suited method to get an objective evaluation of the relaxation data, represented
[0044] by a multi exponential decay,
[0000]
f
(
t
)
=
∑
i
=
1
n
c
i
exp
(
b
i
·
t
)
(
1
)
[0045] is the singular value decomposition (SVD) fitting method. The unknown exponents b i and coefficients c i of Eq. (1) should be obtained from a given set {y j |j=0 . . . [2m−1)} of 2m noisy data points.
[0046] The data values yi as obtained from the T 2 decay, are rearranged in a matrix form having a Hankel structure:
[0000]
H
=
[
Y
0
Y
1
…
…
Y
q
-
1
⋮
⋮
⋯
⋯
⋮
⋮
⋮
⋯
⋯
⋮
⋮
⋮
⋯
⋯
⋮
Y
p
-
1
Y
p
…
…
Y
p
+
q
+
1
]
,
H
i
,
j
=
Y
i
+
j
-
1
[0047] where the indices i and j represent consecutive amplitudes of the echo train. For 2m data
[0048] points, p=q=m. Such matrices are easily factorised using the SVD theorem:
[0049] H=U.Σ.V T , where U and V are orthogonal and Σ is the diagonal singular values matrix. The singular values are directly related to the exponents involved in the decays. This fitting method provides on one hand an objective criterion regarding the number of exponentials existing in a decay curve and on the other being sensitive to the noise level, gives a criterion about the data accuracy.
[0050] Reference is now made to the drawing FIGS. 1 and 2 concerning the results according to a standard processing method of prior art.
[0051] FIGS. 1 a and 1 b illustrates raw data for a sodium image reconstructed in complex mode. FIG. 1 a concerns the real part, whereas FIG. 1 b the imaginary part. Said FIGS. 1 a and 1 b present the Gaussian noise, added to both the real and imaginary parts of the sodium image, as acquired on both channels from an usual imaging experiment. The noise is fluctuating around zero level, having positive as well as negative values. On the other hand, the common magnitude representation of the transformed signals, on FIG. 1 c, produces only positive values, fluctuating around a positive bias level, giving thus the Rician characteristic to the noise. According to the standard method, the noise is highly rectified.
[0052] All data amplitudes, that are further used for quantitative determinations, are situated upon this positive level. The consequences resulting from this noise “rectification” on the decay analysis are easy to be seen when displaying the spin-spin relaxation decays given by the “two relaxation compartments” agarose sample used for this study. The exponentially relaxing compartment is given by sodium ions that are moving almost freely, averaging the quadrupolar interactions with the surrounding electric field gradients (smaller compartment) while the bigger one is relaxing bi-exponentially due to the non-averaged quadrupolar interactions of sodium ions with the macromolecules of agarose. The 32 magnitude echoes give the decays shown in FIGS. 2 a - 2 d for the two compartments, both decays being situated upon the positive bias given by the noise magnitude level. FIGS. 2 a - 2 d shows a Singular Value Decomposition of amplitudes in absolute value concerning two ROIs (Regions Of Interest). FIGS. 2 a and 2 c concern a first ROI, whereas FIGS. 2 b and 2 d concern a second ROI. FIGS. 2 a and 2 b relate to a decomposition without base line extraction. FIGS. 2 c and 2 d relate to a decomposition obtained after base line correction. FIGS. 2 e and 2 f relate to a decomposition obtained after the phase correction procedure which is described from FIGS. 3-5 .
[0053] The corresponding Singular Value Decomposition shows two singular values detaching from noise for both mono-exponentially and bi-exponentially relaxing compartments ( FIGS. 2 a and 2 b ). When tempting to extract the positive bias, the SVD analysis is showing only one singular value for the bi-exponential compartment ( FIG. 2 c ) suggesting that before extraction, the second singular value was characterising the noise positive bias only. It becomes obvious that phase corrected images are required in order to produce accurate quantitative analysis of the relaxation decays on heterogeneous samples as shown in FIGS. 2 e and 2 f.
[0054] Reference is now made to the drawing FIGS. 3-5 concerning a method to correct the phase of images according to the invention.
[0055] The first step for achieving the phase corrected decays according to the present invention, is to plot the amplitudes, for a given pixel, as given by the multiple echoes experiment in the complex plane, i.e. real data array versus imaginary data array. Due to the fact that in a multi-echoes experiment all the echoes have the same phase, this plot is a straight line. Its linear fit will provide the phase of the magnetization created in the considered voxel. FIG. 3 shows a flow chart of an algorithm according to the present invention. The first step 1 concerns the definition of the linear fit. The corresponding rotation angle alpha (α), defined at the step 2 , maximizes the real amplitudes while minimizing the imaginary ones. Screen 7 and 8 show the determination of the linear fit 10 which is the best straight line passing through maximum of points representing amplitudes values of one pixel. After rotation by α, the linear fit is on the real axis. According to a preferred embodiment of the invention, all echoes amplitudes are participating to the angle α definition which improves the accuracy of the phase correction. After performing the rotation for all data with the determined angle alpha, all amplitudes in the complex plane are characterized by imaginary values close to zero, limited only by the S/N value, screen 8 on FIG. 3 .
[0056] The rotation angle so-far obtained can only be considered as an initial value. The accuracy and stability of the algorithm is indeed improved if the rotation angle for the phase correction is optimized by minimizing the imaginary amplitudes at the step 3 . Step 4 concerns a definition of χ 2 which is the sum of the squared imaginary components. This minimization uses a routine of Golden Search, at the step 5 , around the determined value. The final rotation angle with α min is thus determined at step 6 , for each pixel providing the real phase-corrected images. Screen 9 is a representation of the optimization of angle α.
[0057] The phasing procedure is exemplified on FIG. 4 for a given pixel of noisy sodium echoes images obtained for the agarose sample. FIG. 4 a illustrates the experimental data points represented in the complex plane and as a function of time before the phase correction, whereas FIG. 4 b illustrates a similar representation but after the phase correction according to the present invention. The algorithm proves to be very robust even for poorer signal to noise ratio and smaller number of echoes.
[0058] When applying the algorithm according to the invention over the entire images, maximum amplitude real images are obtained while the imaginary one tends to noise level. The results of the phasing routine are shown in FIGS. 5 a - 5 d . FIGS. 5 a and 5 b respectively illustrate real part and imaginary part of raw data for a sodium image after phasing procedure. FIGS. 5 c and 5 d illustrate an example of reconstructed corresponding images. Advantageously, the method according to the present invention can thus be applied to reconstruct sodium image.
[0059] Although the various aspects of the invention have been described with respect to preferred embodiments, it will be understood that the invention is entitled to full protection within the full scope of the appended claims.
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A method for determining phase-corrected amplitudes in a multiple echoes imaging experiment, wherein a Fast Fourier Transform reconstruction is applied to the echo signals generated by a CPMG sequence; for each pixel, the pixel being the same through the echo images, the method including the steps of: plotting the amplitudes of at least two echo images in a complex plane, defining a linear fit from the plot; determining a rotation angle α which is the angle between the linear fit and the real axis of the complex plane; determining the rotation angle α mm which is an optimization of the rotation angle α by minimizing the sum of the squared imaginary components of the amplitudes; and performing a rotation for amplitudes of all echo images with the rotation angle α mm in order to determine the phase-corrected amplitudes.
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INTRODUCTION
[0001] The present invention describes a method to form a radiation pattern and/or a field distribution pattern of electromagnetic and/or magneto-electric fields when operating wholly or partially underwater for purposes including communication, navigation and sensing.
BACKGROUND
[0002] Recent increases in underwater operations have brought diverse associated requirements for communication amongst vehicles, machinery, equipment, instrumentation and people, all or some of which may be underwater when communicating. In addition, requirements for related activities such as navigation and remote sensing of objects have arisen. Although certain means of underwater communication are well known, the nature of the underwater environment severely limits the performance of communication methods conventionally adopted in air or free space. Such methods include electromagnetic and/or magneto-inductive communication, which possesses capabilities that lead it to be preferred for certain applications underwater. For example, it is immune to turbidity that restricts useful optical communication; and to noise, reflection and refraction effects, which limit acoustic communication. However, although electromagnetic communication underwater appears superficially similar to that in air or free space, the forms of antennas adopted are generally significantly different for a variety of reasons, and the properties of the water medium are also considerably different. Discussion of this and other aspects of communication underwater are disclosed in our co-pending patent application “Underwater Telecommunications”, PCT/GB2006/002123, and the details of this are hereby incorporated by reference.
[0003] While offering advantages, one drawback to be considered in electromagnetic and/or magneto-electric communication is the relatively rapid amplitude attenuation of signals with distance, an effect which results from distributed power dissipation arising due to the partially conductive character of water as a propagation medium. Unlike free-space or air, which have essentially no conductivity, typical fresh water in rivers and lakes has a conductivity of around 0.01 S/m (Siemens/metre) or less, and sea water has much greater conductivity of around 4 S/m, with some dependence on salinity and temperature.
[0004] Theoretical analysis and practical experiment both show that such conductivity of the transmission medium gives rise to high signal attenuation encountered over distance when using electromagnetic and/or magneto-electric methods. Consequently, techniques are highly desirable which will maximise the signal strength at a receive site some distance from a transmitter. In some other applications, it may be important to configure fields, which provide other patterns of field distribution, which meet a particular need, such as a degree of omni-directionality over some plane or surface.
SUMMARY OF THE INVENTION
[0005] According to the present invention, there is provided a data communication system comprising a transmitter for transmitting information using electromagnetic and/or magneto-electric transmit antenna, and a receiver for receiving information using a receive antenna, wherein the transmit and receive antennas are formed of a plurality of antenna elements which collectively use field superposition and interference to form field patterns, beams or shapes and wherein one or both the transmit antenna and receive antenna are underwater. Preferably, the field patterns are such as to maximise the signal at the receiver.
[0006] The antenna elements that individually have the characteristics of antennas, are typically distributed in an array of physical positions and may be fed with separate signals from the transmitter, which may be arranged to have differing delays or relative phases, and sometimes differing amplitudes. At distant points, a receiver and its associated antenna will detect an aggregate combination of signals, where the combination is a vector sum of the components. The resultant combined signal will vary with both the distance and angular positions of the receiver.
[0007] The magnitude and phase of the received signal at any particular receive position will depend (amongst other factors) on the relative geometrical positions of the transmit array of antenna elements, the individual field patterns from each antenna element, the wavelength of the signals, the propagation velocity of the signals in water (in turn dependent on wavelength, itself a function of water permittivity and conductivity), the particular phases and amplitudes of the signals which the antenna elements have been given, and the direction and distance of the receive point from the transmit array.
[0008] One or both of the transmit and receive antennas may be underwater and, for the purpose of description, are considered a part of their associated transmitter or receiver. Typically, the antennas are as magnetically coupled conduction loops, but other types of antenna are not excluded.
[0009] Arrays of antenna elements are well known in beam-forming applications in radio and radar systems operating in air or free space. In an important aspect of this invention, it is disclosed how related principles may be used in underwater communication where the propagation properties are different from air or free space, and that they may be adapted to different types of antenna more appropriate for underwater electromagnetic and magneto-inductive operation.
[0010] According to another aspect of the invention, there is provided a composite transmit antenna or a composite receive antenna comprising a plurality of electromagnetic and/or magneto-inductive antenna elements arranged to be operative mutually underwater. Preferably, the antenna elements are electrically insulted. One or more of the antenna elements may comprise a conductive loop antenna.
[0011] The antenna elements may have physical parameters can be changed to alter its field pattern. The field pattern may be changed by altering the phase and/or amplitude of signals fed to or from one or more of the antenna elements.
[0012] The antenna arrays may be employed for the purpose of communicating information and/or sensing the presence of an object underwater and/or navigation underwater.
BRIEF DESCRIPTION OF THE DRAWING
[0013] FIG. 1 shows a communication system with one possible array of antenna elements at a transmitter, including a representation of the field contributions from the elements.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention relates to a method by which a plurality of antenna array elements can create a field pattern in both near-field and far-field components and can be arranged to have a desirable form or shape when operating wholly or partially underwater. Typically, but not exclusively, the field shape will be formed to maximise the signal detected by a distant receiver positioned in a known direction from the antenna array.
[0015] Loop antennas, whose advantages are disclosed in PCT/GB2006/002123, are usually the preferable type to be adopted in the underwater applications typically envisioned. These, or other types of antenna, create field patterns that can be analysed readily and predicted by those familiar with electromagnetic field theory. These analytic techniques are well established but have not previously been applied in field theory textbooks to an underwater environment where the propagation and field properties are mathematically more complex. In particular, the field shapes differ considerably in the conductive underwater medium and, in this environment near-field components must be taken into account for effective communication. By combining the fields of a number of array elements and taking account of their relative positions, the wavelength of the signals (which in water is very different from in air), and the relative phases and amplitudes of the signals delivered to the antenna elements, mathematical analysis can predict an aggregate field pattern. By appropriate design, it is possible to create particular field patterns which are advantageous for certain purposes, the most common of which is maximisation of the field at a distant receive point.
[0016] FIG. 1 shows an array of transmit antenna elements 1 formed of individual elements 2 . Although a linear array of elements is shown for simplicity, other arrangements of elements may be appropriate. Proper representation of fields in amplitude and phase cannot be accomplished adequately on paper. However, in this example the bold arrows shown 3 in direction A represent field components which aggregate to interfere constructively such as to maximise field strength in the vicinity of distant receiver 5 . In contrast, dashed arrows shown 4 in example direction B represent field components, which in aggregate produce only a weak field in the vicinity of a distant point 6 . Other directions are not represented but may be designed to have aggregate signal strengths of various degrees dependent on application.
[0017] Each antenna element may be a waterproof, electrically insulated magnetic coupled antenna, for example a conductive loop antenna. A magnetic coupled antenna is used because water is an electrically conducting medium, and so has a significant impact on the propagation of electromagnetic signals. Ideally, each insulated antenna assembly is surrounded by a low conductivity medium that is impedance matched to the propagation medium, for example distilled water. In applications where long distance transmission is required, the magnetic antenna should preferably be used at lowest achievable signal frequency. This is because signal attenuation in water increases as a function of increasing frequency. Hence, minimising the carrier frequency where possible allows the transmission distance to be maximised. In practice, the lowest achievable signal frequency will be a function of the desired bit rate and the required distance of transmission.
[0018] As previously noted, the particular aggregate field pattern (in distance and angles) from an array of antenna elements is a function of a number of parameters. Methods of finite element analysis (as a practical substitute for analytical mathematics) are well known to those skilled in electromagnetic systems and may be employed in design to calculate and define the field pattern appropriate for a particular application. However, because of the unusual conductive nature of the water medium, adaptation of the usual electric and magnetic field equations is required. While these more complex equations are well known, they apparently have not been applied hitherto to arrays of antenna elements underwater. For proper and complete representation of the fields, both near-field and far-field components must be taken into account. Near-field components are important for low frequency loop antennas used underwater, but this hitherto has not generally been a requirement for arrays of antenna elements in air, because only far-field (propagating) components have been necessary in applications such as radar antennas. The calculations required in finite element analysis underwater are arduous, but amenable to computer methods. The field pattern of each application will have different requirements and require detailed analysis.
[0019] In the theory of antennas, the principle of reciprocity is well known and states that the field pattern of a transmit antenna also applies to a receive antenna of the same construction and operation. Consequently, an array antenna of the type described will often be advantageous also in a receive application, and perhaps may be appropriate for both transmit and receive locations.
[0020] Although most of the foregoing description has adopted a transmit-receive communication link as an example application for this invention, it will be apparent that the method may be applied to any situation underwater or partly underwater where a shaped field pattern is required including, but not limited to, navigation and remote sensing applications. Furthermore, although described for a medium wholly or partly water, this invention also applies advantageously to any other partially conductive medium. It will be understood that the description and examples given are representative only, and that many other related applications and implementations come within the scope of this invention.
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An underwater communication system comprising a transmitter for transmitting information using an electromagnetic and/or magneto-electric transmit antenna and a receiver for receiving information using an electromagnetic and/or magneto-electric receive antenna, at least one of the transmit and receive antennas comprising a plurality of antenna elements which collectively use field superposition and interference to form composite field patterns, beams or shapes and wherein one or both the transmit antenna and receive antenna are underwater.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to supercritical/high pressure fluid processing. More particularly, it relates an apparatus and method for processing work pieces in a supercritical fluid or high pressure liquid environment in a time efficient manner.
2. Prior Art
In the field of microelectronics, semiconductor products such as integrated circuits often undergo processing (for example cleaning) in a supercritical fluid or high pressure liquid, such as, for example carbon dioxide or a mixture of carbon dioxide and a co-solvent. It is necessary for the fluid to be maintained at a controlled pressure and temperature to optimize the process.
Processing of work pieces occurs in a high pressure processing chamber, which must be loaded with the work pieces. One of the major inhibitors to incorporating supercritical fluid or high pressure liquid processing into manufacturing is the low throughput due to long cycle times necessary to pressurize and depressurize the chamber in order to load and discharge the work pieces. Currently, in order to process workpieces in a supercritical fluid (SCF)/high pressure liquid tool, the workpieces must be loaded into the process chamber at ambient temperature and pressure, the tool sealed and then the system must be pressurized by purging the atmospheric air with high pressure fluid which will be brought up to critical processing pressures by pumping on the entire system.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a method and an apparatus for increasing throughput in high pressure fluid processing operations.
The invention is directed to a method for operating a system having a processing chamber for performing an operation at high pressures on an object placed in the chamber. The method comprises storing in a storage chamber a quantity of the fluid at a pressure higher than a pressure at which the operation is to take place, while the processing chamber is depressurized to allow reception of a new object; sealing the processing chamber; and allowing fluid stored in the storage chamber to pass to said processing chamber to re-pressurize the processing chamber before performing the operation. The method may further comprise selecting a pressure to which the storage vessel is pressurized based on relative sizes of the storage vessel and the processing chamber.
The method may further comprise purging the process chamber with the fluid before re-pressurizing the processing chamber. It may also further comprise venting the processing chamber after the operation is performed.
The invention is also directed to an apparatus for processing an object with fluid from a fluid source at high pressure. The apparatus comprises a storage vessel for storing a quantity of the fluid supplied from the fluid source; a pump for pumping the fluid from the fluid source to the storage vessel, the pump having an input connected to the fluid source and an output connected to the storage vessel; a processing chamber in which objects to be processed are placed for processing and from which the objects are removed after processing; a first valve between the pump and the storage vessel; a second valve between the storage vessel and the processing chamber; and an exhaust valve associated with the processing chamber to permit the processing chamber to be vented.
The apparatus may further comprises a bypass for bypassing fluid from the output of the pump to the processing chamber.
The first valve may be a two way valve having an input, a first output and a second output, the input being connected to the output of the pump, and a first output connected to the storage vessel, and the second valve may be a two way valve having an output, a first input and a second input, the first input being connected to the storage vessel, and the output connected to the processing chamber; further comprising a bypass connection between the second output of the first valve and the second input of the second valve. In general, the storage vessel has a larger volume than the processing chamber. The storage vessel is pressurized to a higher pressure than the processing chamber. The storage vessel and the processing chamber are relatively sized, and the processing chamber is pressurized, so that when the second valve is opened and pressure equilibrates between the storage vessel and the processing chamber, the processing chamber is at an operating pressure for performing operations on the objects. The fluid source for the apparatus may be a pressured fluid cylinder or a fluid generator. The apparatus may further comprise a heater for heating fluid stored in the storage vessel and a heater for heating fluid in the processing chamber. The pump may be an air driven liquid pump.
The fluid may be a supercritical fluid, such as supercritical carbon dioxide and may include a co-solvent. Operations may be performed at a pressure of between approximately 700 and 6000 psi (48 to 408 atmospheres).
BRIEF DESCRIPTION OF THE DRAWING
The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic diagram of a system in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is shown a schematic diagram of a system 10 incorporating features of the present invention. Although the present invention will be described with reference to the single embodiment shown in the drawings, it should be understood that the present invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.
In accordance with the invention, a processing chamber 12 of a conventional type such as a reactor bomb manufactured by PARR Instruments of Moline, Ill., may be provided. If the processing fluid is carbon dioxide, it will be supercritical at a pressure of at least 1070 psi (72.8 atmospheres) and a temperature of 31 degrees Celsius. Typical processing pressures may be in the range of approximately 1100 psi to 6000 psi (75 to 408 atmospheres), but may be kept at the center of this range, that is preferably at 3000 psi (204 atmospheres). Other applications may dictate liquid phase processing normally in the range of 800 to 100 psi (54 to 68 atm.).
A heater 13 may be provided to supply heat to chamber 12 to keep it at a required processing temperature. Alternatively, or in addition, the fluid used in chamber 12 may be preheated externally to chamber 12 before being introduced therein, as more fully described below.
System 10 is supplied with fluid from a conventional pressurized fluid source 14 , valved by a conventional valve 15 , such as a pressurized cylinder of a type commercially available and well known in the art. Other sources can be used, depending on the type of fluid. For example, for certain fluids, a fluid generator, which produces the fluid continuously, may be used.
In accordance with the invention, a storage chamber or vessel 16 is provided to store a quantity of the fluid that is being used to process the work pieces. It is preferred that vessel 16 have a volume which is greater than that of chamber 12 , and that it be capable of pressurization to a higher pressure. For example if chamber 12 has a volume of 1 liter, then vessel 16 may have a volume of 3 liters. Vessel 16 may also have associated therewith a heater 18 to heat the fluid stored therein. Heater 18 is shown as an electrical coil heater, but it will be understood that other sources of heat can be used, such as, for example, a combustion heater, or a radiative heat source. This has the advantage of contributing to a substantial reduction in cycle times, as explained below.
Fluid in fluid source 14 is transferred to storage vessel 16 by way of a pump 20 and a valve 22 . Pump 20 may be any of several well know pumps having an appropriate capacity and pressure output rating, such as an air driven liquid pump manufactured by Haskel International, Inc. of Burbank, Calif. Pump 20 may operate virtually continuously in order to perform the functions as set forth below.
Valve 22 is preferably a switching valve having one input and two outputs, with flow directed from the input to one of the two outputs, depending on the position of a control handle thereof (not shown). The input of valve 22 is connected to the output of pump 20 . A first output of valve 22 is connected to a port of storage vessel 16 . A second output of valve 22 is connected to an input of a second valve 24 by way of a bypass conduit 26 . Valve 24 may be of the same construction as valve 22 , but is utilized so that it has two inputs and one output. A first input of valve 24 is connected to a second port of storage vessel 16 . The output of valve 24 is connected to a fluid input port of processing chamber 12 . The second input of valve 24 is connected to bypass conduit 26 , as discussed above.
Processing chamber 12 is also connected to a venting valve 28 which may be used to vent processing chamber 12 .
Operation of the system will be described below with specific reference to lines in the Operations Table set forth below. It will be understood that operations may be conducted manually by an operator, or automatically by a suitably configured automated system, or by some combination of both. For example, suitable pressure gauges and temperature measuring devices may be employed to assure that certain operation steps do not go forward until the proper conditions exist.
At the start of operations, processing chamber 12 is disassembled or otherwise brought to atmospheric pressure and samples to be processed are loaded therein. It is then reassembled in a pressure tight manner. In accordance with step 1 in the Operation Table, valve 28 is opened. Valve 22 is set so that fluid may flow from pump 20 to bypass conduit 26 . Valve 24 is set so that fluid may flow from bypass conduit 26 into processing chamber 12 . Thus, processing chamber 12 is purged of atmospheric gases by the flow of fluid from fluid source 14 .
In accordance with line 2 in the Operations Table, after purging, at line 2 , valve 28 is closed. Valve 22 is set so the output of pump 20 is directed into storage vessel 16 . Valve 24 remains in its previous position so that the output thereof is connected to bypass conduit 26 . The combination of these valve settings effectively isolates processing chamber 12 . It also effectively seals the output port of storage vessel 16 .
While processing chamber 12 comes up to temperature, as a result of heating by heater 13 , pump 20 builds up pressure of fluid in storage vessel 16 by continuously pumping fluid into vessel 16 . After a predetermined pressure has been reached, by waiting a predetermined period of time, or by monitoring the pressure with a pressure gauge, and processing chamber 12 is at the appropriate temperature for processing to occur, the position of valve 24 is changed (line 3 in the Operations Table), thus allowing the pressures in processing chamber 12 and storage vessel 16 to equilibrate, as fluid flows from storage vessel 16 into processing chamber 12 . As long as the pressure in vessel 16 is high enough, and its volume sufficiently large, processing chamber 12 will be filled by the processing fluid to a pressure at which operations in processing chamber 12 can be conducted on work pieces placed therein.
As soon as the pressures in processing chamber 12 and storage vessel 16 have come to equilibrium, the position of valve 24 is shifted, thus isolating processing chamber 12 (line 4 in the Operations Table). However, pump 20 continues to operate, thus increasing the amount and pressure of fluid in storage vessel 16 . The temperature of this fluid is increased appropriately, due to the increasing pressure, and by means of heater 18 , for performing the desired operation on a work piece by means of heater 18 .
When the operation performed on the work pieces in processing chamber 12 are complete, valve 28 is opened, thus venting the processing fluid (line 5 in the Operations Table). It will be understood that the vented fluid may be recovered and recycled for further use by suitable means that do not constitute a part of this invention.
Processing chamber 12 is then disassembled (line 6 in the Operations Table), and the work pieces removed therefrom. New work pieces are loaded into processing chamber 12 . Processing chamber 12 is then again sealed in a pressure tight manner. The position of valve 22 is changed to connect pump 20 to bypass conduit 26 . Venting valve 28 remains open. Valve 24 is positioned so that bypass conduit 26 is in communication with processing chamber 12 , thus purging processing chamber 12 (line 7 in the Operations Table, which is equivalent to line 1 ). As soon as this is accomplished, valve 28 is closed. The position of valve 22 is changed so that the output of pump 20 is again directed into storage vessel 16 . As soon thereafter as processing chamber 12 is close to its intended operating pressure, the position of valve 24 is changed. In a matter of seconds, the pressure in storage vessel 16 and processing chamber 12 come to equilibrium, and the desired operation can be performed on work pieces in processing chamber 12 . Thus, in sharp contrast to prior systems, it is not necessary for pump 20 to begin the long process of directly pressurizing processing chamber 12 . Instead processing chamber 12 is quickly pressurized by a portion of the fluid previously stored and heated in storage vessel 12 .
The process described above, including venting, changing the work piece, and repressurizing, can be repeated any number of times, with time savings occurring during all subsequent cycles. In other words steps 2 - 7 in the Operations table are repeated over and over again until all work pieces have been processed. Thus, the time savings achieved is multiplied by the number of cycles. When all items have been processed and it is time to shut down the system, or when it must be shut down for maintenance or repair, operations are terminated by repeating steps 2 - 5 .
Operations Table
Valve 22
Valve 24
Valve 28
Step
Position
Position
Position
1) Purge
To Bypass 26
Bypass to Chamber
Open
12
2) Initial System
To Storage
Bypass to Chamber
Closed
Pressurization
Vessel
12
3) Pressurize
To Storage
Storage Vessel to
Closed
Processing Chamber
Vessel
Processing Chamber
4) When equilibrium is
To Storage
Bypass to Chamber
Closed
achieved (processing)
Vessel
12
5) Vent
To Storage
Bypass to Chamber
Open
Vessel
12
6) Disassemble reload
To Storage
Bypass to Chamber
Open
and, pressurize storage
Vessel
12
vessel
7) Purge
See (1) above
8) Repeat steps 2-7 as many times as required to process all items in
processing chamber 12
9) To terminate Operations Perform Steps 2-5 then Shut Down
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
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A method and an apparatus, the apparatus including appropriate valves and conduits, for increasing throughput in pressurized fluid processing including storing in a storage chamber of the apparatus a quantity of fluid at a pressure higher than a pressure at which an operation is to take place, while a processing chamber is depressurized to allow reception of a new object; sealing the processing chamber; and allowing fluid stored in the storage chamber to pass to the processing chamber to re-pressurize the processing chamber before performing the operation. The fluid may be preheated in the storage chamber to further reduce processing times.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 11/437,266, entitled FOOTWEAR WITH A SHANK SYSTEM, filed May 19, 2006, now U.S. Pat. No. 7,647,709 which claims the benefit of and priority to U.S. Provisional Patent Application No. 60/682,923, entitled FOOTWEAR WITH EXTERNAL SHANK, filed May 19, 2005, and each of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention is directed to footwear, and more specifically toward footwear that includes a shank.
BACKGROUND
Boots and other footwear are typically constructed of materials that provide a comfortable, durable, and stable platform. Boots, such as hunting and hiking boots, are constructed with an upper connected to a sole assembly. The sole assembly has an outsole, a midsole, an insole, and an internal shank. Conventional boot construction provides a stable product, although additional stability typically results in a heavier product. It is desirable to maintain the durability and stability of a boot while reducing its weight.
SUMMARY
The present invention overcomes limitations of the prior art and provides additional benefits. At least one embodiment of the invention includes a footwear assembly comprising a sole assembly connected to an upper. The sole assembly comprises a midsole made of a first material and having a forefoot portion, an arch portion, a heel portion, and a sidewall extending around a lateral side, a medial side and a heel side of the midsole. A stiffener is connected to the midsole. The stiffener is made of a second material stiffer than the first material. The stiffener has a base portion adjacent to the arch portion and at least one of the forefoot portion and the heel portion of the midsole. The stiffener has a side stabilizer and a heel wrap coupled to the base portion. The side stabilizer is adjacent to the sidewall in at least one of the arch portion and forefoot portion. The heel wrap is adjacent to the heel side and at least one of the lateral side and medial side of the midsole's sidewall. An outsole is connected to at least one of the midsole and the stiffener.
In another embodiment, an outsole is connected to at least one of the midsole and the stiffener. The midsole is made of a first material and has a plurality of lugs projecting away from the upper and defining recessed areas. A stiffener is connected to the midsole in at least some of the recessed areas. The stiffener has a plurality of apertures, and the plurality of lugs project through the apertures. The midsole has a forefoot portion, an arch portion, and a heel portion, and the stiffener is positioned in the arch portion and in at least one of the forefoot portions and the heel portions. An outsole is connected to the lugs.
A detailed description of the illustrated embodiments of the invention is presented below, which will permit one skilled in the relevant art to understand, make, and use aspects of the invention. One skilled in the relevant art can obtain a full appreciation of aspects of the invention from the subsequent detailed description, read together with the figures, and from the claims, which follow the detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a boot assembly having an external shank in accordance with an embodiment of the present invention.
FIG. 2 is an enlarged side view of the boot assembly of FIG. 1 having an external shank.
FIG. 3 is an enlarged bottom isometric view of a boot assembly having an external shank.
FIG. 4 is an enlarged exploded bottom isometric view of the sole assembly of the boot assembly having a midsole and an external shank with an external heel support (the outsole is not shown).
FIG. 5 is an enlarged top plan view of an external shank portion of FIG. 4 shown removed from the midsole.
FIG. 6 is an enlarged side view of a heel portion of the boot assembly of FIG. 1 .
FIG. 7 is an enlarged bottom view of the heel portion of the boot assembly of FIG. 1 .
FIG. 8 is a partially exploded isometric view of a sole assembly in accordance with another embodiment.
FIG. 9 is a bottom plan view of a sole assembly having an external shank in accordance with another embodiment.
FIG. 10 is a side elevation view of the sole assembly of FIG. 9 .
FIG. 11 is a schematic side elevation view of a boot assembly in accordance with another embodiment.
FIG. 12 is a schematic side elevation view of a boot assembly in accordance with yet another embodiment.
FIG. 13 is a right side elevation view of the boot assembly having an external shank.
FIG. 14 there is a left side elevation view of the boot assembly of FIG. 13 .
FIG. 15 is a front elevation view of the boot assembly of FIG. 13 .
FIG. 16 is a rear elevation view of the boot assembly of FIG. 13 .
FIG. 17 is a bottom view of the boot assembly of FIG. 13 .
FIG. 18 is a top view of the boot assembly of FIG. 13 .
DETAILED DESCRIPTION
A footwear assembly having a sole with an improved stiffener, such as a shank, is described in detail herein in accordance with embodiments of the present invention. In the following description, numerous specific details are discussed to provide a thorough and enabling description of embodiments of the invention. One skilled in the relevant art, however, will recognize that the invention can be practiced without one or more of the specific details. In other instances, well-known structures or operations are not shown or are not described in detail to avoid obscuring aspects of the invention. In general, alternatives and alternate embodiments described herein are substantially similar to the previously described embodiments, and common elements are identified by the same reference numbers.
FIG. 1 is an isometric view of a boot assembly 10 having an upper 12 connected to a sole assembly 14 in accordance with an embodiment of the present invention. FIG. 2 is an enlarged side view of the boot assembly 10 . The sole assembly 14 has a lightweight midsole 16 attached to the upper 12 , a shank 18 attached to the midsole to provide longitudinal and lateral stiffness and stability, and a durable outsole 20 attached to the midsole. In one embodiment, a plurality of lugs are formed in the middle and the outsole is attached to the lugs. In another embodiment, the lugs are integrally formed in the outsole and the shank is attached to the outsole around the lugs. In another embodiment, the outsole is provided with lugs or other tread features, and the shank is positioned between the midsole and the outsole. Portions of the shank engage the sides of the midsole or other upper portions of the shoe to provide a platform with improved foot support and/or lateral stability. The sole assembly 14 can also include an insole (not shown) in the interior area formed by the sole assembly 14 and the upper 12 . The sole assembly can also include a conventional longitudinal shank that works in conjunction with the shank 18 of the present invention.
As discussed in greater detail below, the shank 18 of the illustrated embodiment is at least a partially exposed shank (i.e., an external shank), although the shank in other embodiments can be covered by the outsole or other portions of the midsole assembly. As seen in FIG. 2 , the shank can include lateral support portions 21 that extend upwardly away from the outsole and along the side of the midsole 16 . Portions of the shank can extend upwardly along portions of the shoe's upper. In other embodiments, portions of the shank can extend along the upper and connect to the shoe's lace system or other elements of the upper's fit system. The shank can also have support portions in the arch portion and/or forefoot portion on the medial and/or lateral and/or lateral sides. The sole assembly 14 has a forefoot portion 24 to support the toes and forefoot of a wearer's foot, an arch portion 26 to support the arch area of the foot, and a heel portion 28 to support the heel area of the foot. The shank can have support portions in the forefoot portion, the arch portion, and/or the heel portion. For example, the shank can have an external heel wrap 22 coupled to the midsole 16 to help form a stable heel cup.
FIG. 3 is an enlarged bottom isometric view of the boot assembly 10 , and FIG. 4 is an enlarged exploded bottom isometric view of the sole assembly 14 shown separated from the upper 12 ( FIG. 3 ). The outsole 20 ( FIG. 3 ) is not shown in FIG. 4 to avoid obscuring other details shown. The sole assembly 14 of the illustrated embodiment has the midsole 16 made of a molded, closed-cell material, such as EVA (Expanded Vinyl Acetate) or other suitable foam or lightweight compressible material. The EVA material provides a lightweight and durable midsole structure with desirable cushioning and shock-absorbing characteristics. The midsole 16 of the illustrated embodiment has a plurality of protruding lugs 30 formed therein that extend away from the upper. The lugs 30 of the illustrated embodiment are raised portions that extend inwardly from the lateral and medial sides of the midsole 16 . The lugs 30 are provided in the forefoot portion and the heel portion. At least a portion of the midsole's arch portion is free of lugs, as discussed in greater detail below.
The lugs 30 in the midsole 16 of the illustrated embodiment are spaced apart to define a contoured recessed portion 32 formed in the midsole. The recessed portion 32 extends substantially the length of the midsole 16 from the forefoot portion through the arch portion to the heel portion. The midsole 16 of the illustrated embodiment also has an enlarged heel lug 34 positioned in a heel strike area. The enlarged heel lug 34 provides a thick portion of EVA for additional cushioning and shock absorption for absorbing forces, for example, during heel strike. The midsole 16 of the illustrated embodiment also has a plurality of molded channel portions 38 extending generally longitudinally adjacent to the medial and lateral side portions of the midsole. The channel portion 38 extends between the lugs 30 (in the forefoot and heel portions, respectively). Other embodiments can have the channel portions 38 formed in other areas of the midsole, such as the arch portion. The channel portions 38 can be recessed areas that receive portions of the external shank 18 .
In one embodiment, the midsole 16 may be manufactured from a dual density material such that the outer exterior surface of the midsole, particularly along the sidewall, can be a more dense and durable material. The internal portions of the midsole 16 can be manufactured of a less dense material well suited for cushioning and shock absorption. The denser exterior surface of the midsole 16 can help provide for increased durability and wear resistance of the sole assembly 14 .
As best seen in FIGS. 3 and 4 , the outsole 20 of the illustrated embodiment is comprised of a plurality of outsole sections 36 adhered to the bottom surface of the lugs 30 and the heel lug 34 . The outsole sections 36 are, therefore, spaced apart from the recessed portion 32 in the illustrated embodiment. The outsole sections 36 are made of a conventional durable rubber material that has been used for footwear outsoles. The outsole sections 36 are shaped and sized to substantially correspond to the shape of the lugs 30 and the heel lug 34 . Accordingly, the outsole sections 36 of the illustrated embodiment define the surface that engages the ground when the boot assembly is worn by a user. In the illustrated embodiment, the outsole section 36 , connected to the heel lug 34 , wraps upwardly around the midsole's heel portion and is positioned along a sidewall of the heel portion. The outsole sections 36 are adhered to the lugs 30 and heel lug 34 of the midsole by conventional adhesive or other conventional attachment mechanisms. The outsole sections 36 can be contoured to provide additional traction or an aesthetic appearance of the sole assembly 14 .
In the illustrated embodiment, the outsole 20 does not cover the shank 18 . In another embodiment, the outsole 20 is a substantially full-length outsole so that the shank 18 is not visible from the bottom of the boot, except perhaps for lateral and medial stabilizing portions of the shank that extend up along the sidewalls of the midsole at the arch portion, the forefoot portion, and/or the heel portion.
The shank 18 of the illustrated embodiment is a full-length external shank that extends under the forefoot, arch, and heel portions, 24 , 26 , and 28 , respectively, of the midsole 16 . The shank 18 of the embodiment of FIG. 3 is shaped and sized to fit within the recessed portion 32 formed in the midsole 16 . The external shank 18 in another embodiment is also a full-length external shank having a plurality of lug apertures and lugs formed in the outsole extending through the lug apertures in the shank. The external shank 18 of the illustrated embodiment is formed of a fairly stiff material that provides the support and stiffness needed along the longitudinal length of the midsole and laterally while still allowing for a degree of flexibility. Accordingly, the shank does not adversely affect the gait of a wearer. The external shank 18 also provides a durable layer of protection for the bottom of the wearer's foot. In the illustrated embodiment, the external shank is made of Thermo Plastic Urethane (TPU), although other stiff and durable materials, such as plastic or polyurethane, could be used.
In other embodiments, the shank 18 can be less than a full length stiffener. For example, the shank can be a three-quarter length stiffener. The shank 18 in other embodiments can extend through the arch area and through the forefoot area but not the heel area. In another embodiment, the shank 18 can extend through the heel area and the arch area, but not through the forefoot area. The shank 18 can be a unitary member or have components coupled together to provide the longitudinal and lateral stiffness desired while still allowing the midsole to flex and bend as needed throughout the wearer's gait.
The shank 18 of the illustrated embodiment is positioned within the recessed portion 32 formed in the midsole 16 between the lugs 30 . The shank 18 of the illustrated embodiment is fixed to the midsole with an adhesive or other anchoring mechanism. Accordingly, the shank 18 of the illustrated embodiment is substantially fully exposed and is an external component of the sole assembly 14 . As best seen in FIG. 4 , the shank 18 has a plurality of protrusions 42 along the lateral and medial portions that are shaped and sized to fit within the channel portions 38 molded into the midsole 16 . The protrusions 42 act as a positioning device that help retain the shank 18 in proper position on the midsole 16 during the manufacturing of the sole assembly 14 . The protrusions 42 also provide increased surface area to adhere to the midsole 16 . The protrusions 42 further act as longitudinal stiffeners for the shank 18 along the medial and lateral portions of the sole assembly 14 .
The shank 18 of the illustrated embodiment has a forefoot section 44 integrally connected to an arch section of 46 , which is connected to a heel section 48 . The forefoot section 44 has a body portion with a pattern that provides lateral stiffness and stability while also allowing for longitudinal flexibility and bending, such as adjacent to the ball of the wearer's foot. The forefoot section 44 has stabilizing edge portion members 50 that wrap upwardly around sidewall/edge areas 52 of the midsole 16 . The stabilizing members 50 are positioned with recesses 54 molded in the side wall of the midsole 16 adjacent to the edge area 52 . Accordingly, the stabilizing members 50 of the shank's forefoot section 44 in the illustrated embodiment are exposed along the side of the midsole 16 to provide protection to the EVA and to provide visible material differentiation along the side of the sole assembly 14 .
The shape and size of the stabilizing members 50 and the molded recesses 54 in the midsole 16 can be different shapes and sizes, particularly as may be desired, inter alia, for aesthetic and/or support reasons. In other embodiments, the stabilizing members can be configured to extend upwardly along the sidewall of the midsole and engage a portion of the shoe's upper adjacent to the midsole. The stabilizing members 50 on the medial and lateral sides can also be different sizes. For example, the stabilizing member on the lateral side (the outside) is taller or larger to provide increased stability to the outside of the wearer's foot. Other embodiments can have a larger stabilizing member of the medial side.
As best seen in FIGS. 4 and 5 , stabilizing members 50 of the forefoot section 44 each have a break 60 formed therein that makes the sole assembly easier to manufacture and assemble. The breaks 60 also allow the shank 18 and the midsole 16 to be formed with less tolerance. Other embodiments can be constructed without the breaks 60 formed in the stabilizing members 50 of the shank 18 .
The arch section 46 of the shank 18 is positioned within the recessed portion 32 formed in the midsole 16 at the arch portion 26 . The arch section 46 also has stabilizing edge portions or members 51 that wrap around the edges of the midsole and extend upwardly along molded recesses 62 formed in the midsole's sidewall at the arch portion. The arch section 46 in other embodiments can have stabilizing members 51 wrap upwardly along the sidewall of the midsole and along a portion of the shoe's upper. The stabilizing members of the arch section 46 can also be larger or taller to extend higher along the lateral side or the medial sides to provide a desired degree of stability for the user's foot. The size of the stabilizing members 51 on the medial and lateral sides of the arch section can be different depending upon the size of the forefoot sections 44 on the medial and lateral sides.
For example, stabilizing members of the arch section 46 and the forefoot section 44 of the shank on the lateral side can be larger or taller that the respective stabilizing members on the medial sides. Alternatively the stabilizing members 50 of the forefoot section can be larger on the medial side than on the lateral side (e.g., to provide better stability during the toe-off phase of a user's gait), and the stabilizing members 51 of the arch section can be larger or taller on the lateral side than on the medial side (e.g., to provide lateral stability during the transitions in a wearer's gait between heel strike and toe-off). Accordingly, the arch section 46 , which is integrally connected to the forefoot section 44 and heel section 48 , provides a stable arch support area in the sole assembly 14 . In the illustrated embodiment, the arch section 46 has an aperture 64 therein that extends around a logo section molded into the midsole. Other embodiments do not include this aperture for the logo.
In other embodiments, the arch sections 46 of the shank 18 can be partially or fully covered with a portion of the outsole. The arch section 46 can be covered by a layer of resilient outer material that includes a plurality of protruding resilient grip members protruding from the arch area. The grip members of one embodiment are flexible rubber fin structures, although other shapes and materials can be used. The grip members provide additional traction in the arch area. For example, the grip members can provide traction when a wearer steps on a structure (e.g., a ladder rung, an edge of a sidewalk, etc.) in the arch area of the sole assembly. In other embodiments, the arch area of the shank can be provided with texture that can provide increased traction.
The heel section 48 of the shank 18 also has lateral and medial stabilizing edge portions or members 70 that fit within recessed areas 72 molded into the sidewalls of the midsole 16 along the heel portion 28 . The heel section 48 of the shank of the illustrated embodiment has a plurality of apertures 74 that provide a degree of longitudinal flexibility of the external shank in the heel portion 28 while maintaining lateral stability. The stiffness characteristics can be different in other embodiments by providing a shank without the apertures or with larger apertures. The heel section 48 also includes protrusions 76 that fit within the channels 38 molded into the lateral and medial portions of the midsole 16 to facilitate the positioning and retention of the shank.
FIG. 6 is an enlarged side view of the heel portion 28 of the sole assembly 10 , and FIG. 7 is an enlarged bottom plan view of the heel portion. The midsole 16 in the heel portion 28 has a recessed area 66 along the side walls and around the heel portion. The recessed area 66 in the midsole 16 receives a heel wrap section 68 of the shank 18 . The heel wrap section 68 in the illustrated embodiment is integrally connected to the stabilizing member and is made of TPU, although other relatively stiff or rigid materials can be used in other embodiments. The heel wrap section 68 extends around the back of the midsole and provides a stabilizing and protective structure around the heel. The stabilizing members 70 and the heel wrap section 68 form the heel wrap 22 that can help define a heel cup within the boot assembly 10 for improved fit and comfort. The heel wrap 22 of the illustrated embodiment is connected to the heel section 48 of the shank 18 . The heel wrap 22 can be attached to the heel section 48 during manufacture of the sole assembly 14 . In other embodiments, the heel wrap 22 can be integrally connected to the heel section 48 of the shank 18 .
The heel wrap 22 in other embodiments can also wrap upwardly along the side of the midsole and along a portion of the shoe's upper around the heel area. The stabilizing members 70 of the heel wrap 22 can also be larger or extend higher along one side of the shoe (e.g., medial or lateral side) before it wraps around the heel area. For example, the heel wrap 22 can extend higher along the lateral side of the shoe than on the medial side to provide support and stability to the wearer's foot during heel strike. Accordingly, the heel wrap 22 can have an asymmetric configuration. The heel wrap 22 can also be contoured to accommodate the shape of a wearer's heel area for purposes of stability, comfort, and support.
In one embodiment, the shank 18 is formed of a translucent or a substantially transparent material (e.g., a TPU or plastic material). A pattern or image can be provided in or on the midsole so that the pattern or image is visible through the shank 18 . In one embodiment, a camouflage pattern is provided on the midsole, so that the camouflage pattern is visible through the shank 18 .
As best seen in FIGS. 8 and 9 , the outsole material attached to the heel lug 34 provides a surface that engages the ground, such as during heel strike. The outsole material can wrap upward around the heel lug and up the back wall of the midsole at the heel portion 28 . The outsole material covering the heel lug 34 provides a durable heel area of the sole assembly 14 . The outsole material that wraps around the back of the midsole 16 is retained in a recessed area 78 molded into the midsole. Accordingly, the sole assembly 14 has a generally smooth and continuous surface as the sole assembly transitions between the outsole material, the EVA midsole material, and the TPU shank material.
The sole assembly with the EVA midsole and the TPU shank 18 with the rubber outsole 20 provide a very durable and rugged boot having a very lightweight assembly without sacrificing the structural rigidity and performance of a hiking boot, hunting boot, or work boot.
The three materials used in the sole assembly 14 of the illustrated embodiment, namely the EVA, TPU, and the rubber of the outsole, can all have the same color (shown in the illustrated embodiment as being black). In other embodiments, the different materials can be different colors, for example, for aesthetic purposes. The materials for the midsole 16 , the shank 18 , and the outsole 20 can also have different textures to provide a visual difference in these components. Such visual differences can be appealing aesthetically for marketing and other purposes.
In another embodiment, the lugs 30 can be integrally formed in the outsole 20 , and the outsole secured to the midsole 16 ( FIG. 6 ) along an interior surface that faces the midsole. The lugs extend away from the midsole and form the surface that engages the ground. In at least one embodiment, the shank is an external shank attached to an outer surface of the outsole between the lugs, such that the lugs protrude through the shank or appear to protrude through the shank. The shank can include stabilizing members 50 and 51 and/or the heel wrap as discussed above. The shank can be transparent or translucent so portions of the outsole and/or the midsole can be seen through the shank. In other embodiments, only portions of the shank are transparent or translucent.
FIG. 8 is a partially exploded isometric view of a sole assembly 100 of a boot assembly 10 in accordance with another embodiment. FIG. 9 is a bottom plan view of the sole assembly 100 and FIG. 10 is a side elevation view. The sole assembly 100 has a lightweight midsole 102 attached to an upper 104 (shown in phantom lines), a shank 106 attached to the midsole, and a durable outsole 108 attached to the shank 106 . The midsole 102 of the illustrated embodiment is a molded, closed cell, or other lightweight compressible material, such as EVA. The midsole 102 could also be made of a dual-density material, as discussed above.
The midsole 102 has a generally flat bottom surface 110 adhered or otherwise secured to portions of the shank 106 , and an upper surface 112 securely attached to the upper 104 . The midsole 102 has a forefoot portion 114 , an arch portion 116 , and a heel portion 118 . In the illustrated embodiment, sidewalls 120 of the midsole 102 have recesses 133 formed in each of the forefoot portion 114 , the arch portion 116 , and the heel portion 118 . The recesses 133 are shaped and sized to receive portions of the shank 106 , discussed in greater detail below. In other embodiments, recesses can be provided in only one or more of the forefoot, arch, and heel portions. In yet other embodiments, recesses need not be provided in the sidewalls 120 .
The shank 106 of the illustrated embodiment has a forefoot portion 124 attached to the midsole's forefoot portion 114 , an arch portion 126 attached to the midsole's arch portion 116 , and a heel portion 128 attached to the midsole's heel portion 118 . The shank 106 of the illustrated embodiment is a full-length shank formed of a stiff and substantially non-compressible material, such as TPU. Other materials, such as plastics, urethanes, polyurethanes, etc., could be used in other embodiments. Other embodiments can have ¾-length shanks, ½-length shanks, or other size shanks.
The outsole assembly 108 is shown as a two-piece outsole with a forward section 108 A and a rear section 108 B. The forward section is attached to the forefoot portion 124 of the shank and extends forwardly from the arch portion 126 through the forefoot portion. The rear section 108 B is attached to the heel portion 128 of the shank and extends rearwardly from the arch portion 126 through the heel portion. Accordingly, the arch portion of the shank in the illustrated embodiment is exposed. In other embodiments, the front and rear sections 108 A and 108 B can be connected together by outsole material that can partially cover parts of the shank's arch portion. In another embodiment, the outsole can be a full-length outsole that covers the shank from heel to toe. In another embodiment, portions of the shank's forefoot portion 124 and/or heel portion 128 can be exposed.
The outsole assembly 108 of the illustrated embodiment is constructed with a tread pattern that can include lugs or other tread features. Portions of the forward and/or rear sections are constructed with a transparent or translucent outsole material. For example, the transparent or translucent material, such as durable rubber, can be provided between the tread features. Accordingly, portions of the shank can be seen through the transparent or translucent material. The shank can be provided with designs, patterns, text, camouflage, logos, colors, or other visual images that can be seen through the outsole. In other embodiments, the outsole can be made of opaque material.
In the illustrated embodiment, the shank includes the stabilizing members 50 at the forefoot portion, stabilizing members 51 at the arch portion, and the heel wrap 22 at the heel portion as discussed above. The shank in other embodiments can have other configurations or combinations of the stabilizing members and/or the heel wrap. For example, in one embodiment, the shank has the stabilizing members in the arch portion and the heel wrap, but not the forefoot stabilizing members. In another embodiment, the shank only has the heel wrap 22 . In yet other embodiments the shank only has the forefoot stabilizing members.
FIGS. 11 and 12 are side elevation views of other embodiments wherein stabilizing members of the shank extend upwardly from the sidewalls of the midsole and extend along portions of the shoe's upper. The stabilizing members extend along the upper and are connected to the upper's fit system 150 , such as the laces or the like. Accordingly, the shank system supports and cradles the wearer's foot while in the shoe.
FIG. 13 is a right side elevation view of a boot showing an ornamental design of one embodiment of a boot assembly. FIG. 14 is a left side elevation view of the boot of FIG. 13 . FIG. 15 is a front elevation view of the boot of FIG. 13 . FIG. 16 is a rear elevation view of the boot of FIG. 13 . FIG. 17 is a bottom view of the boot of FIG. 13 , and FIG. 18 is a top view of the boot of FIG. 13 .
From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims.
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An aspect of the present invention includes a footwear assembly comprising: an upper and a sole assembly connected to the upper. The sole assembly has a footwear assembly comprising a sole assembly connected to an upper. The sole assembly has a midsole made of a first material and having a forefoot portion, an arch portion, a heel portion, and a sidewall extending around a lateral side, a medial side, and a heel side of the midsole. A stiffener is connected to the midsole. The stiffener is made of a second material stiffer than the first material. The stiffener has a base portion adjacent to the arch portion and at least one of the forefoot portion and the heel portion of the midsole. The stiffener has a side stabilizer and a heel wrap coupled to the base portion. The side stabilizer is adjacent to the sidewall in at least one of the arch portion and forefoot portion. The heel wrap is adjacent to the heel side and at least one of the lateral side and medial side of the midsole's sidewall.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 14/994,671, filed Jan. 13, 2016, which claims the benefit of priority of U.S. provisional application No. 62/103,361, filed Jan. 14, 2015, the contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to paper products and, more particularly, to paper products used in crafting items made with paper.
[0003] Typical paper crafting kits contain parts, which only allow the paper crafter to assemble a standard A2 sized greeting card requiring the user to obtain a separate standard sized envelope. The space available for numerous signatures from well-wishers is limited. They don't take into consideration that numerous people may want to leave personal messages for the recipient for special life events, such as, retirement, birthdays, baby showers, etc.
[0004] While “giant-sized” greeting cards may allow more space for messages, they lack the compact and aesthetically pleasing or formal appearance and do not allow for individual customization.
[0005] As can be seen, there is a need for a customized, oversized decorative envelope, suitable for conveying individual greetings and messages to a recipient from a plurality of well-wishers.
SUMMARY OF THE INVENTION
[0006] In one aspect of the present invention, gift card includes an envelope having a front surface and a back surface joined along a common edge along a binding fold and a closure tab joined to the front surface along a common edge along a closure fold; a first slit defined between an interior surface of the envelope and an exterior surface of the envelope along the binding fold; a second slit defined between the interior surface of the envelope and the exterior surface of the envelope along the closure fold; an insert received in an interior of the envelope; and a ribbon threaded through the first slit and the second slit, such that a first end of the ribbon overlies an exterior surface of the tab and a second end of the ribbon overlies the back surface of the envelope, wherein the ribbon operable to retain the back surface beneath the closure tab with the envelope and closure tab folded in a closed position, and to be retained with the envelope with the envelope in an open position. The binding fold may comprise a first fold and a second fold defining an envelope binding face between the front surface and the back surface.
[0007] In some embodiments, the first slit and the second slit are defined such that the ribbon is positioned substantially laterally across the envelope. In other embodiments, the first slit and the second slit are defined such that the ribbon is positioned diagonally across the envelope.
[0008] In other aspects of the invention, the insert may comprise a matting layer that is adhered to a layering cardstock and is in turn, adhered to at least one interior face of the envelope. The insert may also comprise a cardstock tab adhered to an interior of the envelope along the binding fold. In certain preferred embodiments, the insert comprises a plurality of cardstock tabs having a crease line defined along a common edge of the cardstock tabs, the cardstock tabs joined along the common edge by a binding and an adhesive. The binding may be joined to an interior of the envelope along an interior surface of the binding face.
[0009] Yet another aspect of the invention includes a kit that comprises: a sheet of envelope cardstock; a ribbon; a sheet of layering cardstock; and a sheet of matting cardstock. The kit may also contain a tab cardstock and a binding for joining the tab cardstock, along with an adhesive.
[0010] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of an embodiment of the invention shown in a closed position.
[0012] FIG. 2 is a perspective view shown in an opened position.
[0013] FIG. 2A is a partial perspective view of an alternative embodiment in an opened position.
[0014] FIG. 3 is an exploded view.
[0015] FIG. 4 is a section view of the invention taken from reference line 4 - 4 in FIG. 1 .
[0016] FIG. 5 is an enlarged section view.
[0017] FIG. 6 is an enlarged section view.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0019] Broadly, an embodiment of the present invention provides a customized, oversized decorative envelope, which contains a booklet of large tabs providing a space for personal messages from a plurality of well-wishers. The invention can be retained by the recipient as a keepsake to memorialize the special life event.
[0020] As best seen in reference to FIG. 1 , an embodiment of the present invention comprises a sheet of cardstock that may be formed to the shape of an envelope. The envelope has a front surface 10 and a back surface 14 , joined along an edge, or binding 12 . The edge opposite the binding 12 , may be moved between an open and a closed position, like a book or binder. The envelope may be closed along an edge opposite the binding with a closure tab 16 that folds over a front surface 10 of the envelope. The envelope will have a first interior panel 11 defined between the first and the second score line, and a second interior panel 13 defined between the third score line and an edge of the envelope stock.
[0021] The cardstock may be formed of any desired weight and dimension. For example, a 12 inch square piece of heavy weight cardstock may be cut to size 11¾ inches. The cardstock may be scored in at least two, but preferably three places, to define crease lines for the crafter to conveniently form the envelope with the folds at the correct locations to define the envelope.
[0022] By way of a non-limiting preferred embodiment, when the envelope is to be formed with a binding edge 12 , opposite to the opening edge, the cardstock may be scored in three places. A first score line and a second score line are defined on an exterior surface, with the first score line at approximately 1 inch and the second score line defined at approximately 7.5 inches from left edge of the cardstock. A third score line is defined on an interior surface of the cardstock, with the score defined at approximately 7.375 (7⅜) inches. This will form an envelope approximately 11.75 inches long and approximately 5.5 inches wide. Slits are cut on two of the score lines at the 1 inch and 7.5 inch locations on the exterior of the card through which the ribbon will be threaded.
[0023] The envelope and closure tab 16 may be held in a closed relationship with a length of coordinating ribbon 28 . The ribbon 28 may be tied in a knot or a decorative bow to retain the envelope in a closed condition. The colors for the cardstock and the ribbon 28 may be selected with complimentary colors suitable for the occasion for which the envelope is intended.
[0024] As seen in reference to FIG. 2 and FIG. 3 , a plurality of slots 18 may be cut through the cardstock and the ribbon 28 is threaded through the slots 18 so as to retain the ribbon 28 with the envelope and provide a more formal presentation of the envelope in either the open or the closed position. In some embodiments, the slots 18 may be aligned across the width of the envelope such that the ribbon 28 , when threaded, is perpendicular across the face of the envelope. In other embodiments, such as illustrated in reference to FIG. 2A , the slots 18 may be aligned such that the ribbon 28 is presented diagonally across the front face 10 and the back face 14 of the envelope. When provided as a component of the kit, the ribbon 28 may be cut to a preferred length for the designed thickness of the envelope and any contents and allow for sufficient length for the knotted closure of the envelope.
[0025] The cardstock for the envelope and the ribbon 28 may also be provided as a kit along with one or more inserts. The oversized card-envelope may serve as a base assembly. The inserts may be attached or enclosed within the envelope to form a finished keepsake gift or card. The inserts may include a coordinating matting 20 formed of a cardstock material, which may be adhered to an interior or exterior face of the envelope cardstock. The matting 20 may be provided with a coordinating color, surface texture, or impression, or may be decorated according to the same by the crafter. The matting 20 has a vertical dimension less than that of the envelope and a width that is less than that of the first panel 11 and second panel 13 . The inserts may be provided as an individual sheet or a plurality of sheets when incorporated with the other elements of the invention as a kit.
[0026] The inserts may also include a layering cardstock 22 . The layering cardstock 22 having a length and a width that are dimensioned slightly less than that of the matting cardstock 20 to allow visibility of the coordinating color of the matting cardstock 20 when adhered. The layering weight cardstock 22 may be adhered to the coordinating matting 20 after it has been decorated by the crafter. The layering cardstock 22 may also include an optional ribbon element.
[0027] The inserts may also include a booklet formed of one or more large tabs 26 that may be bound with an adhesive layer 30 and a binding 24 and adhered to the inside of the base assembly between the corresponding score lines, preferably along the binding 12 . The booklet tabs 26 provide individual spaces for message, and can also be decorated with stamped images and/or embellishments to suit the paper crafter's individual taste.
[0028] In certain embodiments, the layering cardstock 22 may be pre-cut and provided with same measurements as the item in photo matting cardstock 20 and adhered to the pre-cut layering weight matte cardstock 22 having the same measurements as the item in matting cardstock 20 and both may then adhered to the inside of the card-envelope base via an adhesive 30 .
[0029] A third piece of pre-cut layering weight cardstock 22 , having approximately the same measurement as the matting cardstock 20 , may be adhered to the third piece of pre-cut layering weight matte cardstock 22 and adhered to the inside of the card-envelope base on the side opposite the greeting or sentiment via an adhesive 30 . The coordinating ribbon 28 can then be used to close the card-envelope base.
[0030] As seen in reference to FIGS. 3 through 6 , an embodiment of the envelope may be formed according to the following. A 12 inch square piece of heavy weight cardstock may be cut to size, scored in three places, and folded to form an envelope approximately 11.75 inches long and approximately 5.5 inches wide. As will be appreciated, the 12 inch square heavy weight cardstock for the base does not necessarily have to be cut down, which will result in the length of the base assembly being 12 inches instead of approximately 11. 75 inches as stated above. Any suitable size could be utilized with the dimensions of the score lines, folds, and inserts adjusted accordingly.
[0031] Slits 18 may be cut on two of the score lines through which the ribbon will be threaded. The length of the slits 18 can be customized to accommodate the width of the selected coordinating ribbon 28 . The front layering cardstock 22 can be adhered to its corresponding matting cardstock 20 and then embellished, stamped, or embossed or likewise decorated according to the paper crafter's or consumer's taste. This decorated assembly layer can then be adhered to the front of the base assembly. The ribbon 28 can then be thread through the slits 18 .
[0032] The layering cardstock 22 for an inside greeting or sentiment can be likewise decorated to taste and adhered to its corresponding matting cardstock 20 . This assembly can then be adhered to the inside of the base assembly. The pre-assembled booklet of tabs 26 can then be adhered to the inside of the base assembly in between the corresponding score lines in the middle fold, or binding 24 of the base assembly. The third set of layering cardstock 22 and its corresponding matte 20 , can be assembled and decorated and adhered to the open side of the inside of the assembly opposite the greeting. The ribbon 28 can then be tied in a decorative bow or knot to close the base assembly.
[0033] An additional piece of ribbon 28 approximately the same length as the base assembly can be used as a place mark or bookmark for the booklet of tabs 26 so persons leaving messages can easily find the next available tab. The entire assembly can be pre-assembled and pre-decorated and sold to consumers with a theme for any specific life event, i.e., baby shower, birthday, retirement.
[0034] In other embodiments, additional tabs 26 can be added to the booklet to hold more space for greetings and messages. If a plurality of tabs 26 are included to form the booklet, a score line 32 may be formed along a common edge of the plurality of tabs 26 and bound with a binding 24 and an adhesive layer 30 . A decorative matching box may also be added to hold the completed assembly.
[0035] The 12 inch square heavy weight cardstock for the base does not necessarily have to be cut down, which will result in the length of the base assembly being 12 inches instead of approximately 11. 75 inches as stated above. The greeting on the inside of the card-envelope base assembly can be placed on either side of the inside. Jute twine, string, or decorative cording can also be used instead of ribbon.
[0036] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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A paper crafting kit containing pre-cut and pre-folded pieces of cardstock, enabling the paper crafter to assemble an oversized decorative paper envelope for greetings and special life events. The envelope may be configured to contain a booklet of tabs for well-wishers to compose personal messages, which can ultimately be used as a gift or keepsake.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a United States National Phase application of International Application PCT/EP2008/002093 and claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2007 016 409.4 filed Mar. 30, 2007, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a lock for a vehicle seat, the lock in a locked state, interacting with a counter element, the lock having a latch which is mounted pivotably about a first bearing bolt and has a receptacle for the counter element and a functional surface and with at least one securing element which is mounted pivotably about a second bearing bolt and, in the locked state, interacts at least temporarily with the functional surface in order to secure the locked state of the lock.
BACKGROUND OF THE INVENTION
[0003] In a lock of this type known from DE 101 15 667 A1, a plurality of components which are movable relative to one another are provided. When tolerances occur or in the event of an impact of such components at a certain relative speed, noises may be produced. It is therefore known through use to provide elastic elements which compensate for tolerances or relative speeds.
SUMMARY OF THE INVENTION
[0004] The invention is based on the object of further improving a lock of the type mentioned at the beginning.
[0005] A lock for a vehicle and a vehicle seat with the lock are provided. The lock, in a locked state, interacts with a counter element. The lock has a latch which is mounted pivotably about a first bearing bolt and has a receptacle for the counter element and a functional surface. The lock has at least one securing element which is mounted pivotably about a second bearing bolt and, in the locked state, interacts at least temporarily with the functional surface in order to secure the locked state of the lock. During the transfer from an unlocked state into the locked state, the counter element approaches the functional surface, and the latch has a contact lug which comes into contact with the counter element, which is approaching the functional surface, before the counter element can come into contact with the functional surface.
[0006] During the transfer from an unlocked state of the lock according to the invention into the locked state, the counter element approaches the functional surface. Since the latch has a contact lug which comes into contact with the counter element, which is approaching the functional surface, before the counter element can come into contact with the functional surface, an impact of the preferably metallic counter element against the preferably metallic functional surface is avoided. A possible formation of noise is therefore reduced. At the same time, the functional surface can continue to be exposed in order, in direct interaction with the securing element or the securing elements, to hold the latch in a manner free from play and to secure the locked state without noise dampers being arranged in the force flux.
[0007] The contact lug is preferably arranged directly adjacent to the functional surface and preferably projects in the direction from which the counter element approaches. The contact lug is of as stiff a design as possible in order to continue to prevent contact of the counter element and of the functional surface even after a small—in particular elastic—deformation. Obstruction of the counter element on its path into the receptacle of the latch is avoided by the contact lug not protruding over the functional surface by much (“height”) in comparison to the other dimensions of the components. The latch is preferably secured by a catching and clamping system, as described, for example, in DE 44 39 644 A1.
[0008] The lock according to the invention is preferably used for a vehicle seat, the backrest of which can be locked to the vehicle structure. However, it may also be used at a different location on the vehicle seat, for example for locking the vehicle seat to the vehicle floor, or at a different location in a vehicle, for example for the locking of doors or engine hoods.
[0009] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] FIG. 1 is an exploded illustration of the exemplary embodiment according to the invention;
[0012] FIG. 2 is a perspective view of the latch according to the invention;
[0013] FIG. 3 is a section through the exemplary embodiment along line III-III in FIGS. 5 and 6 and shown in the locked state;
[0014] FIG. 4 is a section corresponding to FIG. 3 in the unlocked state;
[0015] FIG. 5 is a section through the exemplary embodiment along the line V-V in FIG. 3 ;
[0016] FIG. 6 is a section through the exemplary embodiment along the line VI-VI in FIG. 3 ;
[0017] FIG. 7 is a schematic side view of a vehicle seat; and
[0018] FIG. 8 is a partial view of the exemplary embodiment showing a state during the locking operation;
[0019] FIG. 9 is a partial view of the exemplary embodiment showing another state during the locking operation;
[0020] FIG. 10 is a partial view of the exemplary embodiment showing another state during the locking operation; and
[0021] FIG. 11 is a partial view of the exemplary embodiment showing another state during the locking operation;
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to the drawings in particular, a vehicle seat 1 is provided in a rear row of seats in a motor vehicle. The vehicle seat 1 has a seat part 3 and a backrest 4 which is pivotable relative to the seat part 3 . The backrest 4 can be locked—releasably for the user—to the vehicle structure S of the motor vehicle by means of at least one lock 10 and a counter element B. In this case, the lock 10 can be attached to the backrest 4 and the counter element B to the vehicle structure S, or vice versa. The counter element B is, for example, a bolt or a bar with a round, in particular circular or oval, cross section.
[0023] The lock 10 comprises a housing 12 which, in the present case, is of single-part and half-open design, but may also be in two parts and closed. A first bearing bolt 14 protrudes vertically from the housing 12 and, in the present case, is drawn in the form of a projection out of the material of the metallic housing 12 . The hollow, first bearing bolt 14 supports a pivotable latch 15 . The directional details used below refer to the cylindrical coordinates defined as a result. For interaction with the counter element B, the housing 12 and the latch 15 have a respective receptacle 12 a and 15 a which intersect each other in a locked state of the lock 10 . In an unlocked state of the lock 10 , the latch 15 is pivoted in such a manner that its receptacle 15 a and the receptacle 12 a of the housing 12 are ready to receive the counter element B. The otherwise metallic latch 15 has a cap 17 made of plastic which covers partial regions of the latch 15 , in particular the edges of the receptacle 15 a . The cap 17 can come into direct contact with the counter element B.
[0024] A second bearing bolt 18 which is parallel to the first bearing bolt 14 likewise protrudes vertically from the housing 12 and, in the present case, is likewise drawn in the form of a projection out of the material of the metallic housing 12 . The hollow, second bearing bolt 18 supports a catch element 20 and, offset thereto along the second bearing bolt 18 , a clamping eccentric 22 , said catch element and clamping eccentric both being pivotable independently of each other in the plane of the latch 15 . The latch 15 , the catch element 20 and the clamping eccentric 22 are each prestressed in a pivoting direction, in the present case by means of springs 24 , with the latch 15 being prestressed in its opening direction and the catch element 20 and the clamping eccentric 22 being prestressed in their closing direction. The prestressed clamping eccentric 22 acts in the locked state of the lock 10 by means of a clamping surface 22 a , which is curved eccentrically with respect to the second bearing bolt 18 , in order to exert a closing moment on the latch 15 . A functional surface 15 b of the latch 15 interacts with the clamping surface 22 a , with the angle between the clamping surface 22 a and the functional surface 15 a lying outside the self-locking region. The functional surface 15 b is formed in that region of the metallic latch 17 which is otherwise covered by the cap 17 , but the cap 17 has an aperture at this location in order to permit direct contact with the metallic functional surface 15 b.
[0025] In the locked state of the lock 10 , the catch element 20 is arranged with a catch surface 20 a at a distance from the functional surface 15 b . If, in the event of a crash, the latch 15 exerts an opening moment on the clamping eccentric 22 by means of the forces occurring between the lock 10 and counter element B and begins to open said clamping eccentric, the latch 15 , after a short pivoting distance, comes with its functional surface 15 b into contact with the catch surface 20 a . The angle between the catch surface 20 a and the functional surface 15 b lies within the self-locking region, i.e. the latch 15 cannot exert an opening moment on the catch element 20 . The catch element 20 therefore supports the latch 15 in the event of a crash. The catch element 20 and the clamping eccentric 22 are therefore securing elements. They are both of metallic design.
[0026] To improve the load bearing capacity of the lock 10 , in particular in the event of a crash, in the present case a coupling plate 26 is provided, said coupling plate being placed onto the two bearing bolts 14 and 18 and being secured on the bearing bolts 14 and 18 by means of two securing rings 28 . The latch 15 , the catch element 20 and the clamping eccentric 22 are therefore arranged spatially between the housing 12 and coupling plate 26 .
[0027] The latch 15 has a contact lug 30 laterally offset from the functional surface 15 b , or, more precisely, offset from the functional surface 15 b toward the housing 12 in the axial direction with respect to the first bearing bolt 14 . The contact lug 30 projects in the circumferential direction, i.e. in the pivoting direction of the latch 15 , in relation to the functional surface 15 b , in the present case by approximately 0.5 mm. Since, in the present case, the latch 15 bears a cap 17 , in particular also in the region surrounding the functional surface 15 b , in the present case the contact lug 30 is integrally formed on the cap 17 , i.e. is formed as a single piece therewith. The contact lug 30 is therefore composed of plastic. The contact lug 30 could also be a separately formed component which is fastened to the latch 15 . The contact lug 30 does not have any particular function in the locked state of the lock 10 and during the unlocking operation.
[0028] Starting from an unlocked state of the lock 10 , the unlocked lock 10 and the counter element B approach each other during the locking operation, i.e. during the transfer from the unlocked state into the locked state. In the process, the contact lug 30 moves ahead of the functional surface 15 b . The contact lug 30 comes into contact with the counter element B. The contact lug 30 absorbs the impact and therefore serves as an impact protection means. The material of the contact lug 30 is deformed as little as possible so that the counter element B does not come into contact with the functional surface 15 b . The contact lug 30 therefore prevents formation of noise upon impact of the metallic functional surface 15 b and metallic counter element B with each other.
[0029] Over the further course of the locking operation, the counter element B—owing to a closing pivoting movement of the latch 15 which is acted upon by the counter element B—then passes from the contact lug 30 into the adjoining receptacle 15 a of the latch 15 and to the base of the receptacle 12 a of the housing 12 . The counter element B is then held between an edge region of the receptacle 15 a of the latch 15 and an edge region of the receptacle 12 a of the housing 12 . The catch element 20 and the clamping eccentric 22 —owing to their prestressing—execute a closing pivoting movement toward the latch 15 .
[0030] The latch 15 is secured in the locked state by the clamping eccentric 22 in normal circumstances and by the catch element 20 in the event of a crash. For the unlocking operation, i.e. the transfer from the locked state into the unlocked state, the catch element 20 is first of all opened, i.e. pivoted away from the functional surface 15 b . The clamping eccentric 22 is then carried along by the catch element 20 or the actuating element thereof and is likewise opened. In the present case, the latch 15 opens on account of its prestressing.
[0031] While specific embodiments of the invention have been described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A lock ( 10 ) is provided for a vehicle, particularly for a vehicle seat that interacts with a counterelement (B) in the locked state. The lock includes a catch ( 15 ) pivotally supported about a first bearing pin ( 14 ), having a holder ( 15 a ) for the counterelement (B) and a functional surface ( 15 b ), and at least one securing element ( 20, 22 ) pivotally supported about a second bearing pin ( 18 ). The securing element interacts in the locked state, at least intermittently, with the functional surface ( 15 b ) in order to secure the locked state of the lock ( 10 ). The counterelement (B) approaches the functional surface ( 15 b ), the catch ( 15 ) having a contact lug ( 30 ) that comes into contact with the counterelement (B) approaching the functional surface ( 15 b ) before the counterelement (B) can come into contact with the functional surface ( 15 b ).
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 10/123,255, which is a continuation-in-part of U.S. application Ser. No. 09/933,804, filed Aug. 22, 2001, which is a continuation-in-part of U.S. application Ser. No. 09/842,167, filed Apr. 26, 2001, and which is a continuation-in-part of U.S. application Ser. No. 09/784,238, filed Feb. 16, 2001, and also claims the benefit of U.S. application Ser. No. 60/289,787 filed May 10, 2001 and U.S. Application Serial No. 60/289,786, filed May 10, 2001, the disclosure of each of which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a computer room reduced air flow method and assembly but is not limited to use in computer rooms and instead can be utilized with respect to any equipment assembly requiring cooling which is positioned in a room. The method and assembly described below permits control of the flow of cooling air within equipment assembly and achieving energy savings while reducing the amount of air required to cool electronic/heat generating equipment, where a computer rack heat extraction device (CRHED) or similar device such as a custom air handling unit (AHU) is utilized. The method and apparatus permits the collection of heat generated, for example, by the rack electronic equipment.
[0004] 2. Discussion of the Background
[0005] The conventional computer room method and assembly illustrated in FIG. 1 exemplifies the approach for cooling electronic equipment commonly used currently wherein an array of racks of equipment are positioned on a raised floor. FIG. 1 illustrates an air conditioning system used in the method and apparatus of a conventional system wherein a room space 1 defined by a room floor, sidewalls 3 and a ceiling 4 having a plurality of ceiling panels is provided. The room floor 2 is positioned a predetermined distance above a base floor 5 such that the room floor 2 and the base floor 5 in combination form a double floor structure having a free space 6 (i.e. air passageway) formed therein. A rack 7 for one or more computer processing units (CPU) is disposed on the floor 2 wherein electronic cables for the rack are capable of being housed in the free space 6 of the double floor structure but can be specifically communicated to the rack separate from the free air space if desired.
[0006] In installing each of the CPUs or other equipment on the rack on the floor, a plurality of support members can be provided which are stationary by being fixed by bolts or similar fastening elements to predetermined positions on the floor 2 .
[0007] The rack 7 is positioned in a casing 8 having air inlets 8 a and air outlets 8 b formed respectively in a bottom plate of the casing 8 and in the ceiling portion of the casing 8 . A computer case fan 9 is operable during operation of the equipment 7 so as to assist the air flow upwardly from the casing through the air outlets 8 b . As shown in FIG. 1, the CPU members are arranged in an air passageway formed within the casing 8 . The floor 2 includes a plurality of floor panels located on pedestals 2 b , one panel 2 a of which includes a plurality perforations to allow air flow as indicated by the arrows to freely flow without control through the front of the outside housing of casing 8 , through the CPU rack 7 and out the back passageway or cavity of casing 8 . A cooling unit 14 is positionable either inside or outside the room 1 and is communicated with a heat exchanger or other air conditioning equipment so as to permit a cooling coil 15 located within unit 14 to cool air blowing therethrough. The cooling unit 14 also includes a fan 16 which is positionable below cooling coil 15 . An inlet 20 is provided to allow air from the room to flow thereinto from the room, the air in the casing 8 mixing with room air prior to being introduced into the cooling unit 14 , as illustrated in FIG. 1. The fan 16 is therefore arranged between the air inlet 20 and an air outlet 22 located at the lower portion of unit 14 and feeds air into the free space 6 located above the base floor 5 . The fan 16 thus permits air in the interior of the room to be sucked into the air inlet 20 of the casing 8 and also permits the air in the room to pass through cooling coil 15 . The air in the room is typically at a temperature of 75° F.±.
[0008] The above-noted approach for cooling electronic equipment thus permits the area in the free space 6 below the raised floor 2 to be used for cable management and also serve as a supply air plenum. The computer room air conditioning units (CRACUs) utilize cooling coil 15 to cool the air. The CRACUs supply conditioned air at approximately 55° F. to the under floor supply air plenum or free space 6 . Floor tiles with perforations or slots to allow air to flow from under the raised floor to above the floor are positionable below or are adjacent to the rack 7 . Other perforated tiles are positioned throughout the room to provide air supply to other heat generating equipment and to maintain the room in an ambient environment.
[0009] As illustrated by the arrows in FIG. 1 showing the air flow, the conditioned air is then drawn into the rack 7 by either convection by air flow from perforated panels 2 a into the casing 8 or by fans 9 located in the top of the racks. The air enters the racks at a temperature of approximately 55° F., is heated by the CPUs or other electronics, and flows upwardly out of the rack at approximately a temperature of 95° F. The warm air leaves the rack and mixes with the conditioned ambient environment of the room 1 which is at a temperature of approximately 75° F., and thus returns to the CRACU's at a temperature of approximately 75° F. as illustrated in FIG. 1.
[0010] In view of the foregoing, it can be understood that conventional CRACU's have a 20° delta T (+ or −4° F.) across the cooling coil 15 . This is also coincident with the space delta T which is defined as being the difference in temperature between the air supplied to the space, and the air returned from such space. The temperature of the air returned from the space is usually coincident with the ambient space temperature such that the return air at 75° F. enters the return on top of the CRACU's, passes across the cooling coil 15 and is discharged at a temperature of substantially 55° F. at the bottom of unit 14 so as to pass into the free space 6 . The required air quantity to cool such space is a direct function of the space delta T. The equation set forth below is used to calculate the required air flow or cubic feet per minute (CFM) of air to cool a space:
CFM=BTUH/1.08×delta T
[0011] From the foregoing, it can be appreciated that the disadvantage of the conventional system set forth above requires a significant amount of fan horsepower for operation and thus the need has arisen for reducing the amount of horsepower necessary to operate the fan 16 . In addition, the flow of cooling air across the rack is uncontrolled so as to not necessarily adequately cool each equipment member in the rack 7 .
[0012] The devices of the type described above are exemplified by, for example, by U.S. Pat. No. 5,718,628; U.S. Pat. No. 4,774,631 and U.S. Pat. No. 5,910,045, the disclosure of each of which is herein incorporated by reference, as is the disclosure of provisional application 60/289,787 and 60/289,786, the priority of each is claimed in the present application.
SUMMARY OF THE INVENTION
[0013] One object of the present invention is to provide a flow control device upstream and downstream of the rack so as to effectively and uniformly cool each item of equipment of the rack.
[0014] An additional object of the present invention is to provide a method and apparatus which utilizes an increased delta T to reduce their required air quantity, thus resulting in a reduced airflow method and apparatus. Specifically, the present invention utilizes approximately 40° F. delta T to reduce the CFM by substantially 50%. The substantially 50% reduction in the airflow will serve to effectively correspondingly reduce the required power by substantially 50%, resulting in substantial energy savings. A key element of the method and apparatus is an increase in delta T above what is conventionally used. The present invention is capable of operating in a range of delta T from 25° F. to 45° F. In this regard, it is noted that the use of a 40° F. in the description set forth below is solely exemplary in illustrating device and greater or lesser temperature variations are possible.
[0015] An object of at least one embodiment of the present invention is to provide an air conditioning method and apparatus which utilizes the steps of supplying cooling air generated from a cooling apparatus into an air passageway formed below a floor; guiding the cooling air within the air passageway into an equipment assembly disposed on the floor through an opening located in the floor; communicating the cooling air introduced into the equipment assembly into a plenum and introducing the air released from within the equipment into the plenum for communicating such released air to the cooling apparatus. The method may also include the step of guiding the air from the equipment assembly through at least one duct into the plenum and may include the step of cooling the cooling air generated from the cooling apparatus to a temperature of substantially 55° F. while also heating the air released from the equipment assembly to a temperature of substantially 95° F. prior to introducing such air to the cooling apparatus so as to form a closed loop in terms of cycling of the air through the cooling assembly and the equipment assembly.
[0016] A further object of the present invention is to obtain a temperature differential between the air supplied to the air passageway or plenum from the cooling apparatus and the air introduced into the plenum from the equipment assembly so as to be substantially 40° F., thus permitting lower power requirements of the fan utilized to assist flow of the air in the closed loop.
[0017] A further object of the present invention is to position the fan between the cooling apparatus and the air passageway so as to permit blowing of the air into the passageway towards the equipment assembly, although it is understood that the fan can be located anywhere within the closed loop so as to assist flow of air between the blowing apparatus and the equipment assembly.
[0018] A further object of the present invention is to provide a method and apparatus wherein the cooling assembly is located either within or outside the computer room, the equipment assembly comprising either at least one computer processing unit or other type of processing unit in combination with an additional heat generating equipment or with out such equipment. In addition, a further object of the present invention is to cool equipment assembly generating heat which does or does not include computer equipment.
[0019] An additional object of the present invention is to provide an air conditioning assembly for performing the method described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Various features objects and attendant advantages of the preferred embodiments are illustrated in the figures of the present application which serves to explain the principles of the invention and which includes reference numerals which designate the same or similar elements, wherein:
[0021] [0021]FIG. 1 illustrates an air conditioning method and apparatus used in a conventional system;
[0022] [0022]FIG. 2 illustrates an embodiment of the described in parent application Ser. No. 09/784,238 utilizing a single duct;
[0023] [0023]FIG. 3 illustrates a top plan view for the invention of FIG. 2 showing a plenum for the equipment assembly in an open position;
[0024] [0024]FIG. 4 illustrates the structure of FIG. 3 but wherein the plenum for the equipment assembly is in a closed position; and
[0025] [0025]FIG. 5 shows a rear view of the equipment assembly including a sheet metal plenum which is attachable to the equipment by, for example, a piano-type hinge along one edge thereof which is secured to the equipment assembly with the CPU rack being attachable to the equipment assembly by, for example, quick connect type screws.
[0026] [0026]FIG. 6 illustrates a first embodiment of the equipment assembly and related structure according to the present invention;
[0027] [0027]FIG. 7 is a top plan view thereof with the panels of the equipment assembly of FIG. 6 an opened position;
[0028] [0028]FIG. 8 illustrates a second embodiment of the equipment assembly of the present invention;
[0029] [0029]FIG. 9 is a top plan view thereof with the panels of the equipment assembly of FIG. 8 being shown in an open position;
[0030] [0030]FIG. 10 illustrates a third embodiment of the equipment assembly and related structure of the present invention;
[0031] [0031]FIG. 11 is the top plan view thereof with the panels of the equipment assembly in an open position;
[0032] [0032]FIG. 12 shows a fourth embodiment of the equipment assembly and related structure in accordance with the present invention;
[0033] [0033]FIG. 13 is a top plan view thereof with the panels being shown in an open position;
[0034] [0034]FIG. 14 shows a fifth embodiment of the equipment assembly and related structure of the present invention;
[0035] [0035]FIG. 15 is a side elevational view of the solid panel in the embodiment shown in FIG. 14;
[0036] [0036]FIG. 16 is a top plan view thereof showing the panels of the equipment assembly in an open position;
[0037] [0037]FIG. 17 shows a sixth embodiment of the equipment assembly and related structure of the present invention;
[0038] [0038]FIG. 18 is a side elevational view of the solid panel in the embodiment shown in FIG. 17;
[0039] [0039]FIG. 19 is a top plan view showing the panels of the equipment assembly in an open position;
[0040] [0040]FIG. 20 shows a seventh embodiment of the equipment assembly and related structure of the present invention;
[0041] [0041]FIG. 21 shows a side elevational view of the solid panel in the embodiment shown in FIG. 20;
[0042] [0042]FIG. 22 is a top plan view showing the panels of the equipment assembly in an open position;
[0043] [0043]FIG. 23 shows an eighth embodiment of the equipment assembly and related structure of the present invention;
[0044] [0044]FIG. 24 is the side elevational view of the solid panel in the embodiment shown in FIG. 23; and
[0045] [0045]FIG. 25 is a top plan view thereof showing the panels of the equipment assembly in an open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] FIGS. 2 - 5 shows an air conditioning system used in a method and apparatus according to the invention described in the applications earlier filed by applicants. As shown therein, the room space is defined by a room floor 2 , side walls 3 and upper ceiling 4 , a lower ceiling 4 a formed, for example, of ceiling tiles defining a ceiling plenum 4 b , and a base floor 5 . The room floor 2 is positioned a predetermined distance from the base floor such that the room floor and the base floor 5 collectively form a double floor structure having a free space 6 or air passageway formed therein within which electric cables may also be housed.
[0047] As shown in FIG. 2, air flow from the space 6 can enter one side portion of each of the CPU racks and flow across the same towards a plenum 8 c which can run the full height of the equipment assembly so as to permit air to flow across each CPU in the rack and then flow upwardly towards a plurality of ducts 24 . The ducts 24 are sealed with respect to the equipment assembly by, for example, rubber gaskets 26 with similar rubber gaskets 26 being provided between the duct 24 and the lower ceiling 4 a . Also provided are computer case fans 24 a and 24 b , if desired, to assist in air flow through the ducts 24 . The location of fan 24 b can either be immediately upstream or downstream of the equipment assembly or be positioned at both locations to assist in airflow through the equipment assembly, as would be understandable to one of ordinary skill in the art.
[0048] As illustrated in FIGS. 3 and 4, the plenum 8 c is, for example, made of sheet metal hinged by piano type hinges 8 b to the equipment assembly with the CPUs themselves being capable of being attached to the equipment assembly casing by quick connect type screws or other fasteners.
[0049] As illustrated in FIG. 5, the plurality of ducts 24 can be utilized to help assist airflow to the plenum 4 b formed between ceiling 4 and lower ceiling 4 a . As illustrated in FIG. 2, air flowing from the cooling coil is at substantially 55° F. while the temperature of the air existing from the equipment assembly to the plenum in the ceiling is at substantially 95° F. and is kept separate from the air in the room which is at a temperature of 75° F. The air in the plenum 4 b is fed via a duct 28 downward towards the cooling coil 15 in the cooling assembly 14 and is thus cooled to a temperature of substantially 55° F. Therefore, in the above-noted formula, it can be understood that by doubling the delta T from 20° to 40°, it is possible to reduce by 50% the required airflow or CFM of air to cool the space. Particularly, the reduced airflow approach utilizes an increased delta T to reduce the required air quantity movable by the fan 16 . More specifically, it is proposed to use an approximately 40° delta T to reduce the CFM by 50%, the 50% reduction airflow effectively reducing the required fan horsepower by 50% resulting in substantially energy savings. Based upon experimentation utilized in accordance with the present invention, a key aspect of the present invention is to provide an increase in delta T above what is conventionally utilized with it being noted that the approach proposed by the present invention is workable at a range of delta T from 20° F. to 50° F.
[0050] From the foregoing, it can be appreciated that the cooled supply of air at 55° F. is discharged into the raised floor 2 , the cooled air entering the computer room 1 through, for example, perforated floor tiles in from of or under each CPU rack. A supply of cool air at approximately 55° L will be pulled horizontally or vertically through the electrical equipment cabinet by the CRHED, and discharged into the ceiling plenum at approximately 95° F. such that the 40° F. delta T (i.e., 95° F.-45° F.) comprises the effective space delta T. The CRHED may comprise a sheet metal (or a similar rigid material) housing which is between 3 inches and 6 inches deep and attached to the back of the cabinet/rack. The supplemental fans 24 a , 24 b as part of the CRHED can provide the mechanical means to move the air through the cabinet/rack. Perforated floor tiles can be located at each electronic rack and throughout the room to maintain the room ambient conditions.
[0051] As can be appreciated from the foregoing, the purpose of the device is to collect the heat dissipated by the computer equipment or other equipment generating heat in the rack, and channel it so that the warm air is discharged into the ceiling plenum 4 b . The primary reason for discharging heat into the plenum is to provide a method of returning the warm air (at approximately 95° F.) directly to the CRACU's. The CRACU's will be modified from the conventional configuration shown in FIG. 1 with a return plenum connecting the open return to the top of the ceiling plenum. This completes the closed air loop and allows the CRACU's to take return air at 95° F., cool such air to 55° F. so as to create the 40° delta T required for the reduced airflow.
[0052] An alternate embodiment as part of this approach may use custom air handling units (AHU's). These AHU's serve to replace the CRAHU's to supply conditioned air to the space. The AHU's can be located, for example, in mechanical rooms adjacent to the raised floor space for ducting the supply air under the raised floor, and taking return air from the ceiling plenum. This approach would also allow for the use of an enthalpy economizer allowing for greater energy conservation. Thus, the air conditioning equipment (AHU's and CRACU's) referred to above encompasses the use of an enthalpy economizer or similar device. In addition, a duct directly connecting casing 8 and casing 14 is possible without being located in the ceiling. Here the term “duct” is intended to be the equivalent of plenum.
[0053] In view of the foregoing, significant improvements are provided by the present invention as compared with the conventional approach in that (1) the use of a 40° F. delta T (approximately) to reduce energy consumption is obtainable, (2) the collection of the heat from the electronics equipment with CRHED is possible and (3) it is possible to direct the heat to the ceiling plenum and return it to the CRACU or other AHU, as desired to obtain the efficiencies described above.
[0054] [0054]FIGS. 6 and 7 illustrate a first embodiment of the present invention which is similar in structure and overall operation to that of FIGS. 2 - 5 but wherein the equipment assembly and the structure channeling the flow of conditioned air thereto and the heated air therefrom have been modified.
[0055] [0055]FIG. 6 shows the casing 8 as having an inlet 8 a communicated to an upstream or front plenum 8 e formed in a solid panel 8 f which channels cooled air through the perforated panel 8 d . As can thus be appreciated, in this embodiment a solid plate is utilized within the front door, the plate being tapered or angled in the direction of the flow of air. The angled solid plate allows for a more uniform airflow across the vertical face on the perforated panel 8 d . The more uniform air flow provides for better cooling of the equipment within the rack 7 . Also shown is an outlet 8 b , a back or downstream plenum 8 c , perforated panels 8 d and a rear panel 8 g which forms a hollow channel between the wall thereof and the perforated panel 8 d.
[0056] [0056]FIGS. 8 and 9 illustrate a second embodiment of the present invention which differs from that of the first embodiment in that the outlet duct 24 communicates the heated air back into the room 1 . A fan 24 b can be used to assist the flow in duct 24 towards plenum 4 b spaced from the upper ceiling 4 . Alternatively, in any of the embodiments of the present invention, the duct could communicate the heated air to a position remote from the room or be vented to atmosphere.
[0057] [0057]FIGS. 10 and 11 show a third embodiment of the present invention which differs from the first embodiment only in that the cooled air at 55° F.± is fed into the casing via a ceiling duct 2 a located in the ceiling plenum 4 b and an inlet duct 25 rather than from a position beneath the floor 2 . This is helpful when no access flooring has been installed in the room 1 , for example.
[0058] [0058]FIGS. 12 and 13 are similar respectively to the fourth embodiment shown in FIGS. 10 and 11 but wherein the outlet duct 24 exhausts the heated air into the room 1 via the fan 24 b .
[0059] FIGS. 14 - 16 show a fifth embodiment utilizing the structure shown in FIGS. 6 and 7, but which also includes a rear solid panel 8 h having triangular shaped openings or slots 8 : therein, as viewed in elevation as shown in the elevational view appearing in FIG. 15. In a similar manner, the sixth embodiment shown in FIGS. 17 and 19 correspond, respectively, with the structure shown in FIGS. 8 and 9 wherein FIG. 18 shows the triangular openings 8 i formed in solid rear panel 8 h . Correspondingly the seventh embodiment illustrated in FIGS. 20 and 22, respectively, correspond to the structure shown in FIGS. 10 and 11 and the eighth embodiment shown in FIGS. 23 and 25 corresponds to the structure shown in FIGS. 12 and 13, respectively. FIG. 21 shows an elevational view of the opening 8 in a solid panel 8 h of FIGS. 20 and 22 while FIG. 24 illustrates an elevational view of the opening 8 i in solid panel 8 h of FIGS. 22 and 25. FIG. 15 also shows one inch diameter openings 8 j.
[0060] In each of the embodiments noted above, the flow control and the equipment assembly is advantageous independently of the delta T feature discussed above due to the flow control advantage provided as discussed above.
[0061] The advantage of utilizing a solid plate panel 8 h with triangular openings or slots 8 i adjacent to the perforated plate 8 d in the cavity back door is that such provides equal airflow into the cavity backdoor from the rack-mounted equipment. The use of a solid plate panel 8 h with the specific arrangement of openings 8 i in panel 8 h to the rear perforated plate 8 d equalizes the air-flow into the cavity backdoor thereby providing a more effective heat removal from the rack-mounted equipment. The panel 8 h also has a one inch diameter opening 8 j as shown in FIG. 21. It would be understood that panel 8 h could also be used on the upstream side of the rack 7 if such panel was inverted from the orientation shown in FIG. 15.
[0062] Additional advantages and modifications readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to specific details, and the illustrated examples shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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An air conditioning cooling apparatus and method which includes the steps of supplying cooling air generated from a cooling apparatus into an air passageway formed below a floor; guiding the cooling air in a controlled manner within the air passageway into an equipment assembly disposed on the floor through an opening located in the floor; communicating the cooling air introduced into the equipment assembly in a controlled manner into a plenum and introducing the air released from within the equipment into the plenum and communicating the released air through the cooling apparatus for cooling the released air. The method can permit temperature differential between the air supplied to the air passageway and the air introduced into the plenum from the equipment assembly to be 45° F. to substantially 40° F. so as to reduce the power necessary for operating on the fan of the blowing apparatus, and can also permit a controlled, uniform flow of air to and from the equipment in the equipment assembly.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to drying of particulate carbonaceous material such as coal, lignite, and the like. More particularly, this invention relates to a process for removing water from particulate carbonaceous material by a method which reduces the amount of heat required to obtain a given degree of dryness.
Raw coal as it comes from the mines is frequently subjected to a washing operation, resulting in coal particles having a high degree of surface moisture. This moisture leads to difficulties in handling and shipping, and various methods of dewatering coal have been utilized over the years.
Many lignite materials contain a very high amount of moisture. In some cases, the amount of so-called "inherent" moisture in lignite particles is as high as 65 percent by weight. At least part of this moisture must be removed in order to obtain efficient burning of the lignite and also to reduce the cost of transporting the material.
2. Description of the Prior Art
Several methods for dewatering coal have been practiced over the years. These include methods of mechanical drainage as well as filtration. Other methods used separately or in combination with mechanical water removal include fluid bed drying and other conventional drying techniques. The "Convertol" process in which a coal slurry is mixed with heavy oil and then passed through a centrifugal dryer has been widely used. U.S. Pat. Nos. 2,176,902; 3,381,388; and 3,520,067 are representative of patents describing these prior art processes.
In the drying of materials other than carbonaceous material, it has been proposed to remove water by utilizing a low boiling solvent such as methanol. U.S. Pat. No. 1,687,588 describes a method of drying corrodible materials by repeatedly washing the moist material with alcohol and then evaporating the alcohol from the surface of the particles. U.S. Pat. No. 3,374,550 describes a process for drying a sheet of paper as it is formed by passing the moist sheet through methanol to replace part of the water, followed by drying the sheet of paper in a conventional manner. It is stated that the energy required to obtain the desired degree of dryness is reduced in this manner, or the drying can take place at a lower temperature.
Prior to this invention, there has been no teaching of a method of reducing the moisture content of coal or lignite utilizing a solvent having a low heat of vaporization and low boiling point.
SUMMARY OF THE INVENTION
According to the process of the present invention, particulate carbonaceous material may be dried to a given degree of dryness in a shorter time, or at a lower temperature, or both, than with prior art processes for drying such material. Methanol or other low heat of vaporization solvent is mixed with the moist particulate carbonaceous material to replace part of the water, which may be surface moisture or interstitial moisture, or both, by the solvent which is vaporized more easily than water. The solvent may be mixed with the moist material by spraying it on the material or by passing the material through a tank containing the solvent or simply by covering the material with the solvent and then draining or filtering the solvent, containing part of the original moisture, from the material. The material is then subjected to a drying operation, and the desired degree of dryness is reached in a shorter time or at a lower drying temperature than if the solvent had not been used.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a flow diagram of the process of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The increasing use of wet processing methods in coal preparation plants and the increasing use of high moisture western coals and lignites have increased the need for an efficient process for removing enough of the moisture to enable efficient handling and shipping of the material. It is generally accepted that thermal drying is required to obtain a moisture content of 3 to 6 percent by weight for coal particles, where most of the moisture is surface moisture, or of 15 to 18 percent moisture for lignite particles, where most of the moisture is inherent moisture.
It is apparent that most of the surface moisture on coal particles could be removed by thorough washing with a solvent such as methanol, with the particles then being covered with methanol. What is not apparent is that many advantages are realized in addition to the reduced drying time and reduced drying temperature that are needed to remove methanol as compared to removing water from the surface of the particles. In addition to reduced cost involved in the smaller size dryer required to remove methanol, a more important saving is realized in that the stack gas cleaning equipment required is much smaller, and also the fines-containing gas, which must be removed, is not as hot, and therefore is safer to handle. The obvious disadvantage to utilizing methanol in accordance with the invention is that a solvent recovery system must be provided. However, there are many situations where even though a solvent recovery system must be provided, the overall saving in capital cost and operating cost is considerable when the process of this invention is utilized.
While it is not normally necessary to reduce the moisture content of finely divided coal below about 3 percent, nevertheless even this degree of dryness is difficult to reach using conventional thermal drying techniques. Using the process of this invention, a moisture level of 3 percent is relatively easy to attain when the material being treated is finely divided coal in which the moisture is predominantly surface moisture. In accordance with the invention, coal particles from a water washing process or from a slurry transport system are processed by conventional means such as draining or filtering to remove all but the surface moisture, and the material is then mixed with methanol or other suitable solvent, dried to the desired degree of dryness in a reduced time or at a reduced temperature or with smaller equipment, and the solvent recovered by conventional technology for reuse in treating additional material.
An especially important embodiment of the invention involves reducing the moisture content of lignites prior to shipping the lignite over long distances. As mentioned earlier, some lignites as mined have as high as 65 percent by weight water incorporated therein as interstitial or inherent moisture. This moisture is not removed by filtration or draining. Lignites containing especially high amounts of water do not burn as efficiently as those containing less water, as would be expected. While not all lignites contain as much as 65 percent water, it is not uncommon for the moisture content to be within the range of 38 to 43 percent, which is still very high and contributes significantly to burning inefficiency and transportation cost if the moisture content is not reduced. On the other hand, it is not generally desired to dry lignite to less than 15 to 20 percent moisture, or the material will decrepitate and create excessive fine material, with resultant handling problems.
It has been demonstrated that approximately one-half of the inherent moisture in lignite can be replaced with methanol by a thorough washing of the lignite particles with methanol. Subsequent drying of the lignite particles containing water and methanol proceeds much more rapidly to an acceptable total moisture content. The methanol, which has replaced a portion of the inherent water, is removed much more readily than the remaining inherent water, such that the bulk of the methanol is recovered and the remaining moisture in the dried particles is mostly water.
To illustrate the improved results provided by this invention, a series of experiments was carried out. In these experiments, the results of which are shown in the following Examples 1 through 6, carbonaceous particulate material containing a given amount of moisture (either as water or water plus solvent) was placed in a tray resting on a top loading balance, and moisture removal was determined by measurement of change in weight of the tray and its contents with time. The contents were heated by two 250-watt infrared head lamps directed along the length of the tray. The intensity of the heat was regulated by means of a variable voltage supply. In each of the Examples 1 through 4, a western lignite which had been ground to -14 mesh was used.
EXAMPLE 1
355.0 grams of the lignite was placed under the heat lamps and dried. The initial moisture content (water) of the lignite was 29.0 percent by weight. The setting of the variable voltage supply was 80. The moisture content of the material was reduced to 7.7 percent after 7 hours.
EXAMPLE 2
442 grams of the same lignite as used in Example 1 was slurried in technical grade methanol and filtered. The initial total moisture content (water plus methanol) after filtering was 37.7 percent by weight. Using the same power setting and conditions as in Example 1, the material was dried to 7.8 percent total moisture (water plus methanol) in 3.7 hours. This illustrates that the drying time to obtain a given degree of dryness can be reduced by almost one-half utilizing this invention for this particular material.
EXAMPLE 3
494 grams of the lignite was slurried in crude methanol (84.3 percent methanol) and filtered as in Example 2. The filter cake to be dried contained 46.6 percent by weight total moisture (water plus methanol). After drying for 5.0 hours at the same conditions as in Examples 1 and 2, the moisture content had been reduced to 5.9 percent. Thus, even though the initial total moisture content of this filter cake was higher than the moisture content of the material in Example 1, in which methanol was not used, the cake was dried to a lower moisture content in a shorter time than was required in Example 1.
EXAMPLE 4
512 grams of the lignite was slurried in water and filtered. The filter cake contained 50.9 percent water. After drying for 9.5 hours with the setting of the variable voltage supply at 80, the filter cake contained 12.7 percent moisture. This shows that less moisture is removed from a lignite-water filter cake than from a lignite-water-methanol filter cake at comparable conditions as illustrated in Examples 2 and 3.
EXAMPLE 5
A coal-water slurry was filtered to a 50.0 percent moisture content. The cake was dried at a power setting on the variable power supply of 100. Under these conditions, the water-soaked coal dried to a moisture content of 9.1 percent in 3.0 hours.
EXAMPLE 6
The procedure of Example 5 was duplicated except that technical grade methanol was used in place of water. A moisture content of 9.1 percent was obtained in only 2.0 hours.
EXAMPLE 7
A -1 1/2 + 1/2 inch fraction of lignite having an initial moisture (water) content of 38.6 percent by weight was washed with methanol. After 15 minutes washing, water amounting to 12 weight percent of the sample had been replaced by methanol. After 30 and 60 minutes, respectively, 14 and 19 weight percent had been replaced. The time required to dry a sample, which had been washed in methanol for 15 minutes, to 25 weight percent moisture (water plus methanol) in an induced draft at 160° C was 7.9 minutes, whereas a sample which had not been washed with methanol required 12.3 minutes to reach the same moisture level under identical drying conditions.
Tests indicated that lignite which had been methanol washed and then dried to 25 percent moisture had about the same degree of attrition as lignite that had not been methanol washed.
It is apparent that the process of this invention would not be practical for treating lignite where the total moisture content after drying was 25 percent or so if the proportion of methanol remaining after drying were as high as the proportion prior to drying, which as seen in Example 7 could be approximately one-half of the total moisture content in some cases. However, retention tests to determine the amount of methanol in lignite at 25 percent by weight total moisture (water plus methanol) showed that the amount of methanol remaining in lignite after drying to 25 weight percent total moisture was only about 2 percent. This amount could be reduced even further if necessary.
While methanol was the solvent utilized in all the Examples, it will be appreciated that other solvents having the requisite characteristics of (1) low heat of vaporization, defined herein as less than half the heat of vaporization of water; (2) miscibility with water; and (3) boiling point below 85° C, may be used. Preferred solvents which meet the foregoing criteria are lower molecular weight monohydric alcohols such as ethyl, isopropyl, and tertiary butyl alcohols. For practical reasons, methanol is the preferred solvent for the process of the invention.
The process of the invention, according to a preferred embodiment, is illustrated schematically in the drawing. As shown therein, wet coal and solvent are mixed in a mixing tank, and the mixture is transferred to a dryer, with an optional filtration step between the mixing tank and the dryer. Dried product is removed from the dryer, and vapors are taken overhead from the dryer, combined with filtrate from the filter if applicable, and passed to a solvent recovery step where water is separated from solvent. Recovered solvent is then returned to the mixing tank for reuse in the process. It will be appreciated that lignite could be substituted for coal, and that a draining step could be used in place of or in addition to the filtration step.
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Drying of moist particulate carbonaceous material is facilitated by addition of a nonaqueous solvent having a low heat of vaporization and a low boiling point, such as methanol, to the material followed by application of heat to remove both solvent and water from the material.
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TECHNICAL FIELD
This invention relates to a document dispenser, and more particularly to apparatus and a method of controlling the dispensing of bank notes from a banking machine.
BACKGROUND ART
Automatic banking machines, commonly known as ATM's (automatic terminal machine), are now an accepted way of performing many personal banking financial transactions. There are many reasons advanced for this change from conventional banking for completing financial transactions to the use of automatic banking machines. One of the more significant advantages is its availability on a 24-hour basis, thus providing banking services to a customer at the customer's convenience. The convenience of 24-hour availability, as well as the ability of being operated at numerous locations, where such service would not otherwise be feasible, is possible because such machines are self-operated in that they function on the command of the customer. Because such banking machines are "self-operating", a system must be accurate, substantially error free, reliable, and capable of dispensing bank notes upon command by the customer in a convenient form and in quantities selected by the customer.
With the increased use of automatic banking machines it has become evident that the reliability of such machines is of importance for customer acceptance, particularly when the dispenser is self-operating and unattended in any direct manner. Considerable customer inconvenience may result if a banking machine fails to operate upon the presentation of a customer identification card as a result of the malfunctioning of the system.
It is also important from the operator's (e.g. a bank) point of view that only the correct quantity of bank notes should be delivered to the customer for such automatic banking machines to be acceptable. A banking machine dispensing bank notes must operate to minimize the possibility of delivering more notes to the customer than selected. Some prior art automatic banking machines utilized a "fail safe" operation that shut down the machine upon the detection of a malfunction, such as a bank note misfeed, but such a solution causes obvious inconvenience and loss of service of the machine.
Other prior art automatic banking machines dispense bank notes in selected quantities to a drawer which is subsequently opened to the customer to permit withdrawal of the bank notes. These systems permitted selected withdrawal of varied amounts of bank notes. Once a note is dispensed from a storage bin into the drawer there is no means of retracting the note when an error in dispensing has been made. Such machines require the "fail safe" operation as mentioned previously. Other automatic banking machines provide for the successive counting out of bank notes from a storage bin directly to a customer. The present invention will be described with reference to this type of automatic banking machine although the document dispenser to be described also finds utility when delivering individual bank notes successively to an escrow station. An automatic banking machine with an escrow station operates to deliver bank notes from a storage bin to the escrow station. All bills in the escrow station are then delivered as a bundle to a customer when the correct number has been assembled in escrow.
DISCLOSURE OF THE INVENTION
In accordance with the present invention there is provided a document dispenser that reliably and accurately dispenses bank notes from a storage bin to a customer at an exit throat. Individual notes are fed from the storage bin by means of a vacuum pickup that delivers the note to a transport that selectively returns all but one bank note to the storage bin and transports only a single bill to the customer. Included as a part of the mechanism for picking up individual bank notes from the storage bin is a pivotally mounted pump providing both vacuum and pressure during one cycle of picking up a bank note from the storage bin. As the vacuum pickup lifts the bill into the transport the air pressure ruffles the edge of the note to further insure that only a single bank note is delivered into the transport system.
Further, in accordance with the present invention, accuracy of dispensing bank notes is achieved by actuating a pickup head constrained to move along a path that includes a first rocking motion followed by a linear lifting. The initial rotation of the pickup head is intended to provide more positive separation of the top bank note in a stack.
Although not limited thereto, a document dispenser in accordance with the present invention may include a tamper proof cassette comprising the storage bin. This cassette is equipped with an elevator for continuously positioning a bundle of bank notes therein to an unloading door. However, before the unloading door can be opened or the elevator operated the cassette must be locked in place in the bank note dispenser. This locking in place prior to opening the unloading door and movement of the elevator is provided by mechanical interlock.
In accordance with the present invention, the vacuum/pressure supply for the document dispenser includes a cylinder having multiple chambers each containing a sliding piston. The piston of each chamber is interconnected to the piston in other chambers such that all pistons operate as a single unt. Each chamber incudes a first port opening therein with all such ports located on the same side of the piston in the respective chambers. Each such port is interconnected into a single vacuum/pressure supply source for the document dispenser and connected to a pickup head in the bank note storage bin. The cylinder of the vacuum/pressure supply is pivotally mounted to enable swivel action when driving the interconnected pistons relative to the respective chambers.
Further, in accordance with the present invention, a document dispenser for moving documents from a storage bin into a document transport includes a picker head having vacuum cups for lifting the first document from a stack in the storage bin for delivery into the document transport. To guide the movement of the picker head the document dispenser includes a cam track and a guide track positioned relative to the cam track. A first follower is mounted in the cam track for movement along a path determined by the configuration of this track. A second follower is mounted in the guide track and moves along a path determined by the track configuration. A support carries the picker head to be positioned above the first document of the stack by means of the first and second followers mounted thereto. This constrains the support for movement along a path profile established by the configuration of the respective tracks. To impart to the picker head an initial rotational motion the cam track includes a first camming surface which is contiguous with a second camming surface with the first camming surface establishing the initial movement of a document to the document transport. To impart a pre-established angular orientation to the picker head during movement thereof the guide track and the cam track are positioned at an angle with respect to the top document of the stack.
When provided, the document dispenser includes a cassette having a housing for holding a supply of documents in a stacked configuration. The housing includes a loading door having a locking device and an unloading door also equipped with a locking device. The housing is secured in the document dispenser by locking means prior to unloading documents from the cassette. Responsive to the locking means is an interlock to secure the unloading door in a locked position by means of the locking device when the housing is removed from the document dispenser.
In one embodiment of the cassette of the present invention, the housing thereof includes a main chamber for holding a supply of documents in a stack to be dispensed and also includes a divert chamber for holding documents returned from the document dispenser. The main chamber is provided with an unloading door equipped with a locking device and the divert chamber is provided with a divert door also equipped with a locking device. Both these doors are secured in a locked position by the respective locking devices when the housing of the cassette is removed from the document dispenser.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings.
Referring to the drawings:
FIG. 1 is a pictorial view of a document dispenser in accordance with the present invention showing a storage cassette removed from the dispenser;
FIG. 2 is a partial front view of the dispenser of FIG. 1 taken along the line 2--2 and illustrating the vacuum/pressure supply;
FIG. 3 is a pictorial view partially cut away of the vacuum/pressure pump of FIG. 2;
FIGS. 4-6 are a moving illustration of a document picker mechanism for removing documents from the cassette of FIG. 1 for delivery into the transport of the dispenser;
FIG. 7 is a detail of the cam arrangement for determining the profile path of a picker head for the mechanism of FIGS. 4-6;
FIG. 8 is a sectional view taken along the line 8--8 of FIG. 7 showing the capture of cam followers;
FIG. 9 is a pictorial view of the cassette of FIG. 1 showing the internal elevator mechanism and document width and length adjustment means;
FIG. 10 is a top view in section showing the mechanism for adjusting the width of documents to be accommmodated on the elevator;
FIG. 11 is a sectional view of the width adjusting mechanism taken along the line 11--11 of FIG. 10;
FIG. 12 is a pictorial view partially cut away showing the mechanism for adjusting the length of documents to be accommodated on the elevator of the cassette;
FIG. 13 is a pictorial view partially cut away showing the door lock mechanism of the cassette;
FIG. 14 is a pictorial view for the interlock mechanism for the cassette showing the housing in dotted outline;
FIG. 15 is a section partially cut away of the locking mechanism for the divert door of the cassette;
FIG. 16 is a sectional view partially cut away of the master lock mechanism for configuring the cassette to the ready condition for unloading of documents therefrom; and
FIG. 17 is a sectional view partially cut away showing the elevator adjust mechanism taken along the line 17--17 of FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the document dispenser of the present invention comprises a housing 10 having internal guide tracks 12 and 14 for locating a document storage cassette 16 in an operating position within the housing 10. The cassette 16 includes a loading door 18 which is secured in the closed position by means of a lock 20. For visually checking the supply of documents within the cassette 16 the door 18 is equipped with a vertically oriented window 22 enclosed with a clear plastic or other non-breakable transparent material. The cassette 16 also includes an unloading door 24 which is locked in a closed position, as will be explained, until the cassette is secured within the housing 10. The unloading door 24 is slid to an open position for removing documents from within the cassette 16.
With the cassette 16 inserted into the housing 10 it is secured in place by means of a lock 26 that mates with a permanently mounted key secured within the housing 10 (not shown in FIG. 1). As explained, when the cassette 16 is secured within the housing 10 the unloading door 24 is slid to an open position thereby enabling removal of documents from within the cassette.
Documents are removed from the cassette 16 by means of a picker mechanism 28 and delivered into a conventional belt transport system such as the one illustrated and described in U.S. Pat. No. 3,937,453, issued Feb. 10, 1976. The transport system includes a double detector (not shown) at the input rollers. The belt transport system is driven by means of a motor 32 through a flexible belt 34 connected to a drive pulley 36. Motion of the drive pulley 36 is transmitted to the belt transport system by means of a shaft 38 that extends into the housing 10. Also included as part of the drive mechanism for the belt transport system are drive gears 40 and 42 and drive gears 44 and 46. Details of the belt transport system are not given inasmuch as such transports are now well known in the art.
Included as part of the picker mechanism 28 is a picker arm 48 attached to a picker head 50 that includes vacuum cups, as will be explained. Motion is imparted to the picker arm 48 through a drive link 52 connected to a crank 54 attached to a drive pulley 56. The profile path followed by the picker arm between its two end positions is controlled by the configuration of an upper cam 58 and a lower cam 60 formed in a side plate 55 attached to the housing 10. Riding in each of the cams 58 and 60 are cam followers 62 and 64, respectively, which are held in the cams by the plate 55. A more detailed description of the picker head 50 will be given with reference to FIGS. 4-8.
Referring to FIG. 2, power for driving the picker head 28 is provided by means of a drive motor 66 having a drive gear 68 coupled to a spur gear 70. The spur gear 70 is mounted to a shaft 72 supported in a wall 74 of the housing 10. Connected to the shaft 72 is a pulley 76 which drives the pulley 56 by means of a flexible belt 78.
Also connected to the shaft 72 is an eccentric 80. The eccentric 80 is connected by means of a coupling 82 to a piston rod 84 as part of a vacuum/pressure supply for the dispenser of FIG. 1.
With reference to FIGS. 2 and 3, the vacuum/pressure supply includes a two-part cylinder (86, 88) separated by an end plate 90, thus forming two separate side-by-side chambers. The chamber of the cylinder 86 is capped by an end plate 92 and the cylinder of the chamber 88 is capped by an end plate 94. Mounted within the cylinder 86 is a piston 96 connected to the piston rod 84 to be moved therewith. Coupled to the piston rod 84 within the chamber 88 is a piston 98 such that both pistons move within their respective chambers in synchronism.
As best illustrated in FIG. 3, the respective pistons in each of the cylinders 86 and 88 divides each chamber into an upper section and a lower section. Opening into the lower section of the cylinder 86 is a port 100 that is interconnected by means of manifolding to a port 102 that opens into the lower section of the cylinder 88. Opening into the upper section of the cylinder 88 is a port 104 that provides a vacuum/pressure 180° out of phase with respect to the vacuum/pressure produced at the ports 100 and 102. This vacuum/pressure as developed at the ports 100, 102 and 104 is utilized in the dispenser of FIG. 1 to remove a document from the cassette 16 for delivery into the belt transport system.
Referring to FIGS. 4-6 there is shown a three-part sequence for illustrating operation of the picker head 28 and the vacuum/pressure supply to remove a document from the cassette 16 into the belt transport system. In this sequence of illustrations the transport system is depicted by the input rollers 106 and 108 which are the first elements of the transport system. Mounted within the housing 10 in the lower right-hand corner (as illustrated) is the vacuum/pressure supply including the cylinders 86 and 88. Attached to the end plate 94 is a mounting bracket 110 having a pivot shaft 112 extending therethrough to engage a mounting support 114. The mounting support 114 is attached to the base 116 of the housing 10. The bracket 110, shaft 112, and support 114 provide a pivotal mount for the cylinders 86 and 88. This pivoting action is produced by motion of the eccentric 80 driving the piston rod 84 and enables the use of a rigid piston rod connected to the eccentric 80.
The eccentric 80 along with the pulley 76 rotate in the direction of the arrow 118 to synchronize the operation of the vacuum/pressure supply and the picker head 28.
Upon receiving an actuating command the drive motor 66 rotates the eccentric 80 and the pulley 76 from the position shown in FIG. 4 in the direction of the arrow 118. When the pistons 96 and 98 are at the downward extent of their travel, the picker head 28 is in a position such that the vacuum cups 120 rests against the top document in the cassette 16. As the pistons move from the downward extent of their travel toward the upward extent of their travel a pressure is generated in the port 104 which is connected by means of a line 122 to nozzles 124 and 126. The nozzle 126 is located at the edge of the top document of the stack within the cassette 16 and thus provides a fluid pressure stream against this edge of the document. The nozzle 124 is positioned above the nozzle 126 and also provides a fluid pressure stream directed against the edge of a document. The pressure stream from the nozzles 124 and 126 produce a separation effect on the first document in the stack from the remaining documents. A fluid pressure stream from the nozzle 126 ruffles the leading edge of the top document to provide a more positive separation of this document from the second document in the stack. As the first document in the stack is lifted toward the rollers 106 and 108 the fluid pressure stream from the nozzle 124 provides a second ruffling of the leading edge of the document as a further means of insuring separation of the top document from the second document in the stack. This separation of documents minimizes the possibility of more than a single document being delivered for one motion of the picker head 28 to the rollers 106 and 108.
As the pistons 96 and 98 are moved toward the upward extended position, a vacuum is generated at the ports 100 and 102 which is coupled by means of a line 128 to vacuum cups 120. Thus, at the same time a pressure is being delivered to the nozzles 124 and 126 a vacuum is being generated at vacuum cups 120. With the vacuum cups 120 resting on the top document of the stack an attraction force is developed between the document and the vacuum cups. Motion of the picker head 28 then produces a lifting action of the first document toward the rollers 106 and 108.
Referring to FIGS. 4, 7 and 8, the lifting action is provided by means of rotation of the crank 54 which motion is coupled through the connecting link 52 to the picker arm 48. The initial motion of the crank 54 causes the lower picker arm 48a to rotate counterclockwise about the cam follower 62 in a first segment of the cam 58. Rotation of the picker arm 48a is constrained by the configuration of the cam 60 restricting movement of the cam follower 64.
With reference also to FIG. 5, as the crank 54 rotates into the position as illustrated, the picker arm 48 has rotated and lifted the leading edge of the first document in the stack from the remaining documents. Continued rotation of the crank 54 then produces a linear motion for the picker head 50 in the direction of the rollers 106 and 108. The angle of the picker head 50 with reference to the document stack is determined by the angular position of the cams 58 and 60 as attached to the sidewall 74 of the housing 10. As the picker head 50 moves along the profile path established by the cams 58 and 60, the pistons 96 and 98 continue in an upward direction producing a pressure in the line 122 and a vacuum in the line 128 as indicated by the arrows. This document/movement/pressure relationship continues so long as the picker head moves in the angle as illustrated in FIG. 5 towards the rollers 106 and 108.
With reference to FIGS. 6 and 7, when the picker head 50 reaches its most forward position the document adhering to the vacuum cups 120 will be fed into the nip of the rollers 106 and 108. At this time the crank 54 has rotated approximately 180° and the pistons 96 and 98 are at their upward extent of travel. Continued rotation of the eccentric 80 and the pulley 76 in the direction of the arrow 118 now causes the picker head to be returned to its original at-rest position.
As the picker head 50 starts to return to its at-rest position the piston 96 and piston 98 move downward producing a pressure in the line 128 and consequently at the vacuum cups 120. This pressure produces a positive removal of the document from the vacuum cups and provides a more positive movement of the document through the rollers 106 and 108 into the transport system. A vacuum is now generated at the nozzles 124 and 126 but this vacuum is not utilized in the dispensing of a document from the cassette 16. Picker arm 48 continues to move toward the left along the profile path established by the cams 58 and 60 until both cam followers 62 and 64 are in the far left position. The cam follower 62 both in the forward and reverse directions follows the first surface of the cam 58 and then moves into the second surface contiguous with the first. In the preferred configuration of the cam 58 it provides the initial rotating action of the picker arm 48 by motion of the crank 54.
When the picker arm 48 has returned to its at-rest position the drive motor 66 is de-energized and the system is ready for another command to deliver a document from the stack in the cassette 16 into the rollers 106 and 108 of the transport system. The entire delivery operation is synchronized by motion of the pistons 96 and 98 and the picker arm 48.
Referring to FIG. 9, there is shown the cassette 16 with the door 18 in an open position for loading documents into the cassette. Internal mechanism within the housing 130 of the cassette 16 includes an elevator 132 for supporting documents as they are removed from the cassette through the unloading door 24. Also included within the cassette is an adjustment mechanism 134 that is positionable to accommodate various lengths of documents (bank notes) on the elevator 132. There is also included within the housing 130 an adjusting mechanism 135 for adjusting the width of documents supported on the elevator 132. This mechanism will be discussed with reference to FIGS. 10 and 11.
The lower portion of the housing 130 includes an enclosure 136 containing a locking device and interlocks for controlling operation of the cassette 16. Included as part of this locking and interlock mechanism is the door lock 20, a cassette lock 138 and a locking knob 140. The lower portion of the housing 130 above the enclosure 136 comprises a divert bin 142 for storage of documents returned from the transport system for various reasons such as the moving of two documents together through the transport system.
Referring to FIGS. 10 and 11, there is shown the mechanism for adjusting the width of a document supported on the elevator 132. Basically the width adjustment mechanism is an arrangement of parallel bars that move a guide plate 144 and guide bands 146 and 148 relative to the sidewalls of the housing 130. The guide plate 144 is attached to the sidewall of the housing 130 by double hinges 150 and 152. Each of these double hinges extends substantially the length of travel of the elevator 132 such as shown in FIG. 9 for the double hinge 152. Each of the guide bands 146 and 148 are similarly supported on double hinges 154 and 156, respectively. These hinges are attached to the sidewall of the housing 130.
With specific reference to FIG. 11, there is shown the mechanism for adjusting the position of the guide plate 144 and the guide bands 146 and 148. The double hinges 150, 152, 154 and 156 are pivotally mounted to a support plate 158 that in turn is mounted to the sidewall 130 of the cassette housing by means of fasteners 160 and 162 mounted in elongated slots 164 and 166, respectively. These elongated slots 164 and 166 are in a bracket 168 extending downwardly from the plate 158.
Pivotally mounted to the bracket 168 is an adjustment lever 170 that includes a positioning pawl 172. The positioning pawl 172 engages a serrated adjustment bar 174 mountd to the sidewall of the housing 130, such as shown in FIG. 9. The adjustment lever 170 is spring loaded into engagement with the serrated bar 174 by means of a spring 176. A finger tab 178 attached to the lever 170 enables an operator to adjust the distance between the plate 144 and the bands 146 and 148 by a single motion.
To make the adjustment to accommodate various widths of documents on the elevator 132, the finger tab 178 is rotated to lift the positioning pawl 172 free of the serrations in the bar 174. By pulling or pushing on the finger tab 178 the support plate 158 is moved relative to the housing walls of the cassette 16. This causes a change in the angular configuration of various segments of the double hinges 150, 152, 154 and 156, thereby moving the plate 144 and the bands 146 and 148 closer together or farther apart to accommodate different widths of documents on the elevator 132. By releasing the finger tab 178 the positioning pawl 172 again engages the serrations in the bar 174 to establish a fixed distance between the plate 144 and the bands 146 and 148.
Referring to FIG. 12, there is shown in detail the adjustment mechanism for accommodating various lengths of documents on the elevator 132. Attached to the guide plate 144 are guide brackets 182 and 184. In addition to including a guide channel 186 the guide bracket 182 also includes a channel 188 having a serrated section 190. Slidably mounted within the channel 188 is a U-shaped adjustment bar 192 having a positioning pawl 194 for engaging the serrated section 190. One end of the U-shaped adjustment bar 192 is attached by means of a hinge 196 to an end bar 197. The second end of the U-shaped adjustment bar 192 is attached by means of a hinge 196 to an adjustment tab 202. The adjustment tab is constrained to move within a slide bracket 204 which is attached to an end bar 197.
Also attached to the end bar 197 by means of the hinge 200 is a guide bar 198 slidably mounted within the channel 186.
Mounted to the adjustment bar 197 below the bracket 204 is a hinge 206 which extends into a guide bar 208. The guide bar 208 is slidably mounted within a channel 210 of the guide bracket 184.
To adjust for the length of documents on the elevator 132 the tab 202 is pushed upward to disengage the adjustment pawl 194 from the serrated section 190. The end bar 197 can then be positioned by sliding the guide bars 198 and 208 in their respective channels. When the position of the bar 197 accommodates the length of documents on the elevator 132 the tab 202 is released thereby allowing the positioning pawl 194 to engage the serration section 190.
To load documents onto the elevator 132 the end bar 197 is rotated in alignment with the guide plate 144 by means of the hinges 196, 200 and 206. Thus, by means of the finger tab 178 and the tab 202 both the width and length may be adjusted to accommodate various sized documents (bank notes) in the cassette 16.
Referring to FIG. 13, to provide a tamper-proof cassette the door 18 is provided with latch togs 210 positioned along the edge of the door 18 opposite the hinge mounting. When the door is in the closed position the latch togs 210 pass through openings 212 in the end wall of the housing 130. Slidably mounted within the housing immediately inside the end wall is a sliding bar 214 that includes openings 216 equal in number to the openings 212. The sliding bar 214 is mounted to the housing 130 by means of a fastener 218.
Extending from the lower portion of the sliding bar 214 is an L-shaped section 220 that includes a cam 222. The cam 222 is engaged by a cam follower 224 mounted on a rotating cylinder 226. The cylinder 226 is part of the lock 20 and rotates in the direction of the arrow 228 by means of the key 230.
When the door is in the closed position an operator rotates the key 230 thereby causing the sliding bar 214 to slide upward in the direction of the arrow 232 to cause the openings 216 to secure the latch togs 210 and thus the door 18 to the housing 130. Thus, the door 18 is now in a locked position insuring the security of documents within the cassette 16.
Referring to FIGS. 14-16, there is detailed the lock and interlock mechanisms for securing the cassette 16 within the dispenser to provide a tamper-proof configuration. Shown within the chamber 136 is the lock 138 which operates an interlock shaft 234 extending to a dispenser lock 236. The dispenser lock 236 is positioned to engage a key 238 that is permanently secured in the dispenser of FIG. 1. As the cassette is slid into place within the dispenser the key 238 engages the lock 236. Rotating the lock 138 locks the key 238 within the lock 236 thereby securing the cassette within the dispenser.
With specific reference to FIG. 15, attached to a coupling 240 as part of the shaft 234 is a pin 242. This pin engages a slot 244 within a latch bracket 246 attached to the end wall of the housing 130 by means of a fastener 248. The bracket 246 is rotatably mounted by means of the fastener 248. Rotating the coupling 240 with the shaft 234 also rotates the bracket 246 in a clockwise direction as viewed from the inside of the cassette 16.
With the bracket 246 in the position as illustrated in FIG. 14 it provides a lock for a divert door 250. The divert door provides access to the divert bin 142 of the cassette 16. This door will be opened only when the cassette 16 is in an operating condition for removal of documents through the unloading door 24. Thus, when the lock 138 is rotated causing the shaft 234 and the coupling 240 to likewise rotate the bracket 246 rotates to clear the divert door 250. Note, however, that the divert door is still in the closed position.
Rotatively mounted to the bottom of the housing 130 of the cassette 16 is an X-shaped locking lever 252 that has attached to one arm thereof the locking knob 140. The locking lever 252 is constrained from rotating by means of an arm 252a engaging the shoulder of a lock stop 254. This lock stop 254, as best shown in FIG. 16, is secured to the shaft 234 and rotates therewith by means of the lock 138. Rotating the lock 138 to secure the cassette 16 within the dispenser by means the lock 236 and key 238 also rotates the lock stop 254 90 degrees clockwise from the position shown in FIG. 16. This frees the arm 252a from the obstruction caused by the lock stop 254 and pushing the locking knob 140 toward the lock 20 causes the locking lever 252 to rotate from the position shown. The locking lever 252 will then be in the second of its two stable positions.
To maintain the locking lever 252 in its first and second stable positions, a spring 298 is attached to one end to the bottom of the housing 130 by means of a pin 300 and at the opposite end to the locking lever 252 by means of a pin 302. The spring 298 thus provides a toggle action for the locking lever 252 to provide two stable positions thereto. The one stable position is as illustrated in FIG. 14 and the second stable position is with the locking knob 140 moved toward the lock 20.
Attached to one arm of the locking lever 252 is a sheathed cable 258 by means of a swivel coupling 256. The sheathed cable is attached to the bottom and side walls of the housing 130 by means of mounting clips 260.
The second end of the sheathed cable 258 is attached to the divert door 250 by means of a bracket 262. By rotating the locking lever 252 from its stable position as illustrated in FIG. 14 to its second stable position the lower half of the divert door 250 is rotated upwardly thereby providing access to the divert bin 142 such as shown in FIG. 1.
Attached to an arm of the mounting lever 252 opposite the locking knob 140 is a sheathed cable 264 by means of a swivel coupling 266. The sheathed cable 264 is attached to the housing 130 by means of brackets 268.
The end of the cable 264 opposite the coupling 266 is attached to an L-shaped bracket 270 rotatively mounted to the sidewall of the housing 130 by means of a pin 272. Opposite the attachment of the cable 264 on the bracket 270 is a pushrod 274 that engages a notch 276 within the unloading door 24. With the pushrod 274 inserted into the notch 276 the unloading door 24 is secured in the closed position thus preventing access to documents within the cassette 16. The lock position of the unloading door 24 is illustrated in FIG. 14.
The second arm of the bracket 270 terminates in a locking pawl 278 that is positioned to engage an elevator chain 280 as part of the lift mechanism for the elevator 132. When the locking pawl is in the position shown the elevator chain cannot be moved thereby preventing operation of the elevator 132. Thus, when the cassette is removed from the dispenser and the locking knob 140 is in the position illustrated in FIG. 14, the pushrod 174 locks the unloading door 24 into a closed position and the locking pawl 278 secures the elevator in its last position.
When the cassette is secured into the dispenser by means of the key 238 engaging the lock 236 the locking knob 140 is movable to its second position thereby rotating the locking lever 252. Rotating the locking lever 252 causes rotation of the bracket 270 to release the locking pawl 278 from the elevator chain 280 and also to displace the pushrod 274 from the notch 276. This enables an operator to open the unloading door 24 preparing the cassette for the dispensing of documents therefrom.
Referring to FIG. 17, with the elevator chain 280 locked by means of the pawl 278 the elevator 132 is positionable manually within the cassette by means of a pull tab 282. The pull tab 282 is formed at one end of a slidably mounted bracket 284 secured to the underside of the elevator 132. The bracket 284 is spring loaded into the position illustrated by means of a spring 286 attached to a tab 288 as part of the bracket 284 and a tab 290 secured to the underside of the elevator 132.
At the end of the bracket 284 opposite the pull tab 282 there is attached a U-shaped retainer 292 that encircles the elevator chain 280. The U-shaped retainer 292 includes positioning buttons 294 that engage the chain 280 when in the position shown. When in this position the elevator 132 will move up or down with movement of the elevator chain. To position the elevator 132 manually, the pull tab 182 is moved in the direction of the arrow 296 thereby releasing the positioning buttons 294 from the chain 280. The elevator 132 may now be raised or lowered in the cassette 16 and the pull tab released. Releasing the pull tab re-engages the positioning buttons 294 to engage the chain 280.
Although a preferred embodiment of the invention has been illustrated in the accompanying drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiment disclosed but is capable of numerous rearrangements, modifications and substitutions without departing from the scope of the invention.
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Automatic terminal machines for banking transactions utilize a document dispenser for delivering bank notes to a customer. The document dispenser moves the bank notes from a storage bin by means of a picker mechanism that moves along a path profile established by the configuration of a pair of cam tracks and associated cam followers. The picker mechanism includes vacuum cups for lifting the first document from a stack in the storage bin for delivery into a document transport. Connected to the vacuum cups is a vacuum/pressure supply that includes a multiple chamber cylinder that provides both vacuum and pressure synchronized with operation of the picker mechanism. The piston is pivotally mounted to enable swivel action when driving the interconnected pistons in respective chambers. When provided, the document dispenser includes a cassette having a loading door and an unloading door, each separately equipped with a locking device. These locking devices provide a tamper-proof cassette configuration when the cassette is removed from the dispenser for servicing. The various locking devices are released by locking the cassette housing into the document dispenser.
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BACKGROUND OF THE INVENTION
This invention relates to scaffolding and in particular to hardware for quickly erecting an adjustable scaffold using common building site materials. The scaffold apparatus is compact and lightweight and may be conveniently stored by a workman in an easily portable box in kit form.
The building trades have long sought a means for quickly constructing a light, safe and versatile scaffold that was substantially independant of the face of a building for its support. Formerly, scaffolding that was designed for either limited contact with a building or independently supported was either too cumbersome, or limited in application.
Conventional timber scaffolding relies upon a timber frame having spaced pairs of vertical posts providing a four point ground support, horizontal longitudinal ledgers, and horizontal transverse members. The planks upon which the workmen stand are supported by the transverse cross members. Longitudinal and transverse cross bracing is provided to stabilize the structure. This type of scaffolding utilizes a substantial amount of timber, is space consuming, and is fixed in height requiring reassembly or multiple ledgers and transverse members for variations in height.
Trestle supports have been devised to provide some adjustment in height. The horizontal members which support the platform planks span pairs of vertical column members which are adjustably supported in pairs of A-frames. However, the height to which the vertical column members may be raised is limited, becoming unstable at much of the height necessary in construction of even moderately-sized buildings.
Tubular scaffolding has become popular for use in much of modern construction. The scaffolding is modular in construction for raising to exceptional heights and has a basic configuration similar to timber scaffolding. Members are tubular in form and designed to provide staging in height increments by a socket attachment of standard end frames into the top ends of identical end frames. Spaced pairs of end frames are interconnected by easily connected cross bracing. Tubular scaffolding is effective but requires a large investment and is bulky, requiring a substantial storage capability. It is inconvenient for many job sites where the available space for scaffolding is limited and is often too much of a problem to obtain and erect for minor and moderate construction projects.
Suspended scaffolding comprises a pair of horizontal putlogs that support the plank members. The putlogs are suspended by cables attached to overhead outrigger beams. The putlogs are generally equipped with two drum mechanisms having ratchet devices which act as winches to raise and lower the putlogs and plank members. While relatively compact for storage, the scaffolding lacks the stability needed for many construction tasks.
The disadvantages of conventional scaffold devices have been obviated by the scaffolding apparatus described hereinafter, which has been devised to provide a stable support for a working platform which is easily and conveniently erected and which is easily stored and transported to and from the jobsite and is suitable for inclusion in the working tool kit of even the individual tradesman.
SUMMARY OF THE INVENTION
The scaffold apparatus of this invention comprises a set of hardware having as its principal components a pair of support brackets which provide a cantilever support for a working plank. The support brackets or plank brackets are attachable to a conventional timber preferably comprising a common two by six framing plank.
Hardware for erecting and supporting the timber is attached to the timber before raising the timber to a vertical post position adjacent to but dispaced from the building. A collar slideable on the end of each of the two necessary timbers includes a plate for attachment to a convenient upper portion of the building to maintain the timber in a vertical position. A brace socket is attached to opposite faces of the timber and hingedly retains the end of a two by four cross brace segment near the upper end of each timber. After raising the timbers, the braces can be connected to opposite brace segments attached to the lower end of the timbers.
Each support bracket has an elongated horizontal cantilever leg upon which the workman's plank is supported. On the bracket at the base of the cantilever leg is a bearing heel. Directed generally opposite from the cantilever leg is a lag foot with a bearing roller mounted at its distal end or toe. The bearing heel and bearing roller contact, respectively, the fore and aft edges of the vertical timber in bracketing fashion. The lag foot is angled upward from the horizontal providing a cant to the two bearing points such that weight upon the leg of the bracket torsionally locks the bracket on the timber.
A spring loaded clamping mechanism having a displaceable contact surface is drawn directly opposite the cantilever leg and bearing heel such that the contact surface is cocked against the aft edge of the timber on a compression line with the bearing heel. Ears on the bearing heel, the distal end of the lag foot and the clamping mechanism prevent the bracket from disengaging from the timber.
A cable extending to the top of a building is connected to the support bracket in such a manner that pulling on the cable unlocks the clamping mechanism and allows the bracket to be raised, guided by the bearing roller and bearing heel. The bearing roller has a freewheel mechanism to roll in one direction and the bearing heel is canted to bite into the timber in the downward direction such that the bracket is easily raised, but unable to inadvertently fall when an upward lift ceases.
To lower the bracket, the vertical direction of the cable from the point of engagement with the bracket is changed by a line segment from the distal end of the cantilever leg which connects to the cable. This provides a bifurcated support which alter the line of lift causing a tilt to the bracket along with the uncocking of the clamping mechanism. The bearing roller is removed from contact with the timber and the bearing heel becomes flush with the timber edge allowing the bracket to be lowered.
Raising or lowering the two brackets and the working plank can be accomplished simultaneously or alternately.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of one of the plank brackets of the scaffold apparatus.
FIG. 2 is a side elevational view of the opposite side of the plank bracket of FIG. 1 with clamping mechanism engaged.
FIG. 3 is an exploded view of the roller assembly.
FIG. 4(a) is a cross sectional view taken on the lines 4(a)--4(a) in FIG. 1.
FIG. 4(b) is a cross sectional view as in FIG. 4(a) with clamping mechanism engaged.
FIG. 5 is a partial fragmentary view with clamping mechanism engaged.
FIG. 6 is a perspective view of a support hardware.
FIG. 7 is a perspective view of a bracing hardware.
FIG. 8 is a schematic view of the scaffold apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1 and 2, the principal element of the scaffold apparatus, a plank bracket 10 is shown. The plank bracket 10 is arranged with a mirror image plank bracket in a parallel spaced orientation on vertical support timbers 12, one of which is shown in phanton in FIGS. 1 and 2. The pair of plank brackets support a horizontal plank 13 here shown in phantom in a preferred embodiment as a lightweight, elongated banana board conventionally used as a working platform adjacent a structure under construction. The plank 13 is set between two bracketing stops 14 and 15 for stability.
The plank bracket 10 is fabricated from an aluminum casting in a generally I-configured cross section having an elongated cantilever leg 16 projecting horizontally from a base portion 18. Oppositely projecting at an upward angle from the cantilever leg 16 is a lag foot 20 which is integral to the casting of the leg 16 and base portion 18.
Referring to FIG. 2, the base portion 18 of the plank bracket includes a bearing heel 22 which is attached to the base portion 18 by bolts 24. The bearing heel 22 comprises a hardened steel T-section having a mounting face 26 oriented in a specific manner by two threaded locating holes 28 in the base portion of the bracket. The T-section bearing face 30 shown in dotted line is perpendicular to the mounting face 26 and oriented at approximately a four degree angle from the perpendicular by the locating holes 28 such that the lower outer edge 32 is biased toward the support timber 12. This slight cant allows the edge 32 to "bite" into the side edge 34 of the timber to prevent slippage of the plank bracket. The T-section is symmetrical and includes auxilliary mounting holes 35 to allow the T-section to be reversed if the original biting edge becomes worn.
A bearing roller 36 at the distal end or toe 38 of the lag foot 20 operates in conjunction with the bearing heel 22 to locate the plank bracket on the timber 12. Because of the angular orientation of the lag foot 20, weight upon the cantilever leg 16 torsionally locks the plank bracket on the timber. The bearing roller 36 comprises a freewheel assembly shown in the exploded view of FIG. 3 and includes a roller 40 having a knurled or gear-like outer surface 42 to increase the coefficient of friction and a sawtooth twelve-point inner surface 44 that rotates on a cast journal 46 having a pair of grooves 48 in which ride a pair of gravity-located ball bearings. In this arrangement the roller 40 is free to rotate on the journal 46 in only one direction. The freewheel assembly is designed to allow the roller to roll when the bracket 10 is moved in the upward direction but lock in the downward direction. The case journal 46 is fastened to the toe 38 of the lag foot 20 by a bolt 50 and includes a projecting ear 52 which hooks around the timber 12 as shown in FIG. 2.
Similarly, a portion of the mounting face 26 of the T-section bearing heel 22 provides a locking ear 54 that hooks around the timber 12 and cooperates with the ear 52 on the lag foot 20 to collar the timber 12 and prevent side slip or disengagement of the bracket from the timber. The distance between the respective ears 52 and 54 is sufficiently greater than the width of the timber to allow for initial installation of the plank bracket on the timber when the foot is horizontally oriented.
Referring again to FIG. 1, a spring loaded clamping mechanism designated generally by the reference numeral 56, insures that the bracket is locked on the supporting timber 12. The clamping mechanism 56 includes an elongated rod 58 guided adjacent the web portion of the bracket casting through a guide hole (not visible) in the base portion 18 of the bracket casting and a guide hole (not visible) in a trunnion 60 fixed to the web portion 62 of the bracket casting. The rod 58 extends from the bracket leg 16 and terminates in a handle 64. At the opposite end of the rod between the trunnion 60 and an E-clip and washer 66 is a compression spring 68 which compresses when the handle 64 and rod 58 are drawn from the bracket leg 16. The handle 64 and rod are rotatable in the guide holes. The handle includes a flat clamping face 70 and retaining ear 72 such that when the handle and rod are withdrawn as shown in FIG. 1, it can be rotated 90 degrees and relaxed to a release point with the clamping face 70 pressing against the timber and the ear 72 preventing disengagement as shown in FIG. 2. It is evident that the clamping action of the clamping mechanism locks the bracket in place on the timber.
While the bracket may be moved up and down on the timber by direct manual manipulation in first releasing the clamping force by drawing back the handle and then lifting the bracket to raise, or then tilting the bracket to displace slightly the one-way roller from the timber to lower, the plank bracket may be raised or lowered remotely.
Since it is often the case that the bracket cannot be directly raised or lowered because of its inaccessible height, a means has been devised to raise or lower the bracket from above, or from the ground by a common hoisting rope 74. With additional reference to FIGS. 4(a), 4(b), and 5, a short cable 76 of predetermined length is anchored by a cable ferrule 78 in a protruding boss 80 in the base portion 18 of the bracket. The cable 76 passes behind the rod 58, around pulley 81, upwardly through a hole 82 and vertically to a ring terminal 84 which can be connected to the hoisting rope 74 by a clip 86 on the rope.
On the rod 58 in the area of the cable passage across the leg of the bracket, is a projecting roller and pulley assembly 87 comprising a shaft 88 welded to the rod normal to the axis of the rod, a washer 89, a small pulley 90 mounted on the shaft 88 adjacent the washer 89, a second washer 91, a small roller 92 mounted on the shaft adjacent the second washer 91, and a self-locking nut 93. In the web portion 62 of the bracket leg 16 is a recess 94. As shown in FIGS. 4(a) and 4(b), the recess 94 does not completely go through the web portion 62 because of a thickening ramp 96 at the end of the web portion on one side of the bracket as shown in FIG. 2.
In the position of the handle and rod shown in FIG. 1, the roller and pulley assembly is aligned with a turn key portion 98 of the recess 94. In this position, it is possible to rotate the handle pivoting the roller and pulley assembly into the turn key portion 98 as shown in FIGS. 4(a) and 4(b) such that the roller 92 is movable in a guide way portion 100 of the cutout. In this position, the pulley 90 begins to interfere with the cable. As the handle and rod is relaxed into clamping position, the pulley 90 draws back the cable as shown in FIG. 5. When the hoist rope is pulled, the cable tautens by the weight of the bracket and by action on the pulley, forces the rod slightly in a retracted direction thereby releasing the clamping force at the handle on the timber. The roller 92 contacts the upper wall of the guide way portion and prevents rotation of the rod. In this manner the bracket can be lifted.
To lower, not only must the clamping action be relieved, but the brackets must be tilted as mentioned before. This is accomplished by a cable segment 102 which is permanently fastened to the distal plank stop 15. The cable segment is of a predetermined length such that when attached to the main cable ring 84, it shifts the direction of tension sufficiently to cause a tilt or cant to the plank bracket without interfering with the releasing capability of the main cable and the roller and pulley assembly. This cant is necessary to disengage the one-way bearing roller 36 from the edge of the timber and remove the "bite" from the heel bearing 22 such that the bearing face 30 is flush with the edge of the timber and guides the plank bracket as it is lowered. By simple use of a pulley or simply a capstan post at the top of the structure under construction, the hoist rope can be manipulated from the ground.
While the plank bracket comprises the principal element in the scaffold hardware, it is advantageously used with additional hardware to facilitate erection of scaffolding.
Referring now to FIG. 6, a collar assembly is shown for support of the timber 12. It is preferred that the timber used for the bracket assembly comprise a conventional two by six plank. However, use of a three by six of four by six is possible with adaptors for the roller and heel bearing and a substitute handle. In using the preferred timber stock, the collar assembly is provided with a rectangular tube section 112 dimensioned compatible with the cross sectional dimensions of the two by six such that the collar assembly is snug but free to slide along the length of the two by six. The tube section 112 is pivotally connected to a mounting plate 114 by a pair of connecting links 116 and 118 and pin 120. The mounting plate 114 can be directly fastened to the facia of a structure by duplex nails 122 through pre-existing holes 124 in the plate. Alternately the plate because of its pivotal nature can be fastened to a horizontal outrigger element tied off to the structure by raising the plate to a horizontal position, or fastened to a downwardly sloped member attached to a pitched roof by again adjusting the position of the mounting plate.
The collar assembly positions the timber vertically without inhibiting longitudinal movement where most stresses are usually generated as the scaffolding settles at its footing.
In FIG. 7, a brace socket 126 is shown. The brace socket 126 includes a rectangular tube section 128 dimensioned to receive the end of a two by four brace 129 segment as shown in phantom. The tube section 128 is pivotally attached to a yoke 130 by pivot pin 132. The yoke 130 is rigidly connected to a mounting plate 132 which is fastened to the face of the timber 12. The brace socket is centrally mounted on the timber face to allow the bracket to pass up and down the timber without the projecting ears on the plank bracket contacting the brace socket. The two by four is retained in the socket and the mounting plate is mounted on the timber 12 by duplex nails 134 in pre-existing holes.
The manner of assembly of the scaffolding is described with reference to the schematic illustration of FIG. 8. A pair of brace sockets 126 are attached to each timber. Brace segments 129, preferably no longer than the timber height to the brace sockets, are installed and left loose against the timber. A collar assembly 110 is slipped over the end of each timber and retained temporarily by a removable rail. The plank brackets may be installed at this time or after raising the timbers. The timbers are raised, the nail removed and the mounting plates attached to appropriate structures. A second brace segment 136 is fastened to the foot of each timber by a single duplex nail and laid horizontally on the ground. The brace segment 129 in the hinged socket on one timber is joined with the brace segment 136 attached to the foot of the opposite timber by raising the free ends of both segments and nailing in a straight line diagonal. One or more additional nails are placed in the foot connection to firm up the bracing. The plank brackets are installed, a banana board placed on the brackets and the brackets raised to an appropriate height in the manner described. The brackets may be installed such that the plank brackets and working plank either face the building or face away from the building depending on the available space for the timber and the attachment point to the structure.
As noted the two brackets are a mirror image of one another or an isomeric duplication such that the lag foot of each bracket is on the outer side of the two parallel spaced timbers. In this manner the two brackets will avoid contact with the hardware for the cross bracing. The two brackets, together with two collar assemblies, and two brace sockets are intended to be provided in kit form to the user. Timber for the vertical members and cross bracing is intended to be utilized from the job site or obtained separately.
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A scaffold apparatus usable in conjunction with conventional on-site building materials to provide an adjustable scaffold, the scaffold apparatus having a matched pair of plank brackets with a releasable clamping mechanism adapted to clamp the brackets to a pair of spaced timber posts, the plank brackets having cantilevered arm portions extending from the post on which a horizontal cross plank is supported, the brackets having an adjustment mechanism cooperating with a cable for raising and lowering the brackets and cross plank on the timber posts, the plank brackets in combination with additional hardware for supporting and bracing the timber posts forming a compact scaffolding kit.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a magnetic recording medium such as a magnetic tape and magnetic disc, in which a hexagonal system ferrite powder is used as a recording element.
2. Description of the Prior Arts
Requirement for a high density recording of a magnetic recording medium increases year by year. A horizontal recording medium in which acicular magnetic powder is orientated in a magnetic layer has a disadvantage that a rotational demagnetization significantly increases as a recording density is increased. At present, therefore, a vertical magnetic recording medium in which signals are recorded in a vertical direction to a magnetic layer has been developed.
As a magnetic layer formed in such a vertical magnetic recording medium, a layer which is formed by painting platelet particles of hexagonal system ferrite powder, orientating them in parallel to a medium surface is considered to have better properties, such as productivity and durability, than a thin metal layer consisting of a magnetic metal such as Co-Cr.
However, a conventional magnetic recording medium using the hexagonal system ferrite powder has a fatal disadvantage that it has an unsatisfactory storage property since an output of recorded signals attenuates, namely so called "demagnetization by cooling" occurs, when the recording medium is subjected to a low temperature and reproduced at room temperature after signals are recorded.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a magnetic recording medium with an improved storage property, which does not have the disadvantage of the conventional magnetic recording medium using hexagonal system ferrite powder as the recording element.
In the course of study to overcome such disadvantages, it has been discovered that coercive force of the magnetic recording medium using the hexagonal system ferrite powder greatly varies with a storage temperature and shows such temperature dependency that the coercive force is high in a low and high temperature range and minimum in a moderate temperature range. In addition, it has been also discovered that, in the conventional magnetic recording medium of this type, since the coercive force is minimum at a temperature below -20° C., it decreases as the temperature decreases in the room temperature range, which causes the demagnetization by cooling.
In view of such findings, various magnetic recording mediums which exhibit various temperature dependency of the coercive force have been produced by varying a chemical composition of hexagonal system ferrite powder and the like, and a relationship between the demagnetization by cooling of the medium and the above temperature dependency has been studied. Then it is found that the medium which exhibits such temperature dependency that the coercive force is minimum in a specified temperature range, has significantly reduced demagnetization by cooling, present invention.
Thus, the provides a magnetic recording medium which has a magnetic layer comprising a hexagonal system ferrite powder on a substrate, and is characterized in that the magnetic recording medium exhibits a temperature dependency that a coercive force of the magnetic layer is high at a low and high temperature range and minimum at a moderate temperature range, and a coercive force is minimum at a temperature between -20° and 50° C.
According to the present invention, there is provided a magnetic recording medium which comprises a substrate and a magnetic layer comprising hexagonal system ferrite powder of the formula:
AO·n{[Fe.sub.1-(x+y) ·M.sup.2+.sub.x ·M.sup.4+.sub.y ].sub.2 O.sub.3 } (I)
wherein
A is at least one metal selected from the group consisting of Ba, Sr, Pb and Ca,
M 2+ is at least one divalent metal ion selected from the group consisting of Mn, Co, Ni, Cu, Zn and Mg,
M 4+ is at least one tetravalent metal ion selected from the group consisting of Ti, Zr, Sn, Ge, V and Nb,
n is a number of 3 to 8,
x and y are such numbers that x+y is from 0.02 to 0.3 and x/y is from 0.2 to 0.8.,
and which has a temperature dependency such that the coercive force of the magnetic layer is at a minimum in the temperature range of -20° to 50° C. and has a higher coercive force outside of this temperature range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph which shows temperature dependency of the coercive force of the magnetic recording medium according to the present invention, and
FIG. 2 is a graph showing ranges of M 2+ (x) and M 4+ (y) which give hexagonal system ferrite powder to be used according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The magnetic recording medium of the present invention is characterized in that it exhibits such temperature dependency that the coercive force is minimum in the moderate temperature range, namely in a temperature range of -20° to 50° C. FIG. 1 shows the temperature dependency of the coercive force in the magnetic recording medium produced in Example 1 of the present invention, in which the coercive force is minimum at 10° C.
As is clear from FIG. 1, since the medium exhibiting the above temperature dependency has a small change of the coercive force in the room temperature range and the coercive force is not deteriorated as atmospheric temperature is lowered, demagnetization by cooling is significantly suppressed. Further, since the change of the coercive force is small, demagnetization by heating is also suppressed. Thus, since the medium of the present invention has small change of the coercive force caused by the temperature change near room temperature, it has good storage property when it is used in a circumstance that the temperature significantly changes according to seasons such as in Japan or according to location.
In contrast, in the conventional magnetic recording medium in which the coercive force is minimum at a temperature lower than -20° C., usually not higher than -100° C., the coercive force greatly decreases as the temperature decreases in the room temperature range, and the demagnetization by cooling significantly occurs. This is easily recognized by shifting the coercive force curve of FIG. 1 to the left direction, namely to the direction of lower temperature. In the medium in which the coercive force is minimum at a temperature higher than 50° C., the coercive force greatly decreases in the room temperature range as the temperature increases, and the demagnetization by heating significantly occurs.
In the magnetic recording medium of the present invention, the demagnetization by cooling is suppressed and no demagnetization by heating occurs. Therefore, the medium has good storage property. Among the mediums, one having the minimum coercive force in the temperature of -10° to +30° C. is most suitable.
The magnetic recording medium of the present invention is easily produced by selecting the chemical composition of the hexagonal system ferrite powder which is used as the recording element. The suitable ferrite powder is expressed by the formula:
AO·n{[Fe.sub.1-(x+y) ·M.sup.2+.sub.x ·M.sup.4+.sub.y ].sub.2 O.sub.3 } (I)
wherein,
A, M 2+ , M 4+ , n, x and y are the same as defined above.
When x+y which corresponds to a proportion of substituted iron is smaller than 0.02, an effect of decreasing the coercive force is small. When it is larger than 0.3, it is difficult to hold the easily magnetized axis in vertical direction to the platelet surface, and magnetization component in vertical direction to the medium is insufficient.
When a ratio of the M 2+ and M 4+ (x/y) is in the range of 0.2 to 0.8, the medium has good storage property. That is, the medium exhibits such temperature dependency that the coercive force is minimum at a temperature between -20° and 50° C. and has reduced demagnetization by cooling heating. When the ratio (x/y) is in the range of 0.3 to 0.6, the medium exhibits such temperature dependency that the coercive force is minimum at a temperature between -10° and 30° C. and it has very good storage property.
When the ratio (x/y) is larger than 0.8, the medium exhibits such storage property that the coercive force is minimum at a temperature lower than -20° C., thus it has large demagnetization by cooling. The conventional magnetic recording medium uses the hexagonal system ferrite powder in which x/y is usually 1, therefore, it is considered to have the significant problem of demagnetization by cooling. When x/y is smaller than 0.2, the medium exhibits such storage property that the coercive force is minimum at the temperature higher than 50° C., thus it often has the problem of demagnetization by heating.
By using, as the recording element, the hexagonal system ferrite powder which has such chemical composition that the ratio of x and y (x/y) in the above formula is from 0.2 to 0.8, preferably from 0.3 to 0.6, the magnetic recording medium with good storage property is easily obtained.
The coercive force of the ferrite powder is preferably in the range of 200 to 2,000 Oe. When the coercive force is smaller than 200 Oe, the high density recording cannot be realized. When it is larger than 2,000 Oe, the ferrite powder is not suitable as the recording element of the magnetic recording medium. A hexagonal platelet of the ferrite powder preferably has an average length along major axis of 0.02 to 0.5 μm. When the average length along major axis is smaller than 0.02 μm, it is difficult for the ferrite powder to have sufficient magnetism. When it is larger than 0.5 μm, the surface smoothness of the magnetic layer is worsened and the high density recording cannot be realized.
The hexagonal system ferrite powder is prepared by using a specified amount of a compound such as chloride which contains each metal (Fe, A, M 2+ , and M 4+ ) of the formula (I). An aqueous solution of the compound is added to an aqueous alkaline solution and mixed to form a precipitate, which is heated at the temperature of 150° to 300° C. for 1 to 6 hours. A reaction product is washed, filtered, dried and thermally treated at 400° to 1,000° C. for several hours so as to improve the magnetic properties.
The magnetic recording medium of the present invention can be prepared, for example, by mixing and dispersing the hexagonal system ferrite powder with a binder resin, an organic solvent and other additives to prepare a magnetic paint, coating the paint on a substrate such as a polyester film with any coating means such as roll coater, and drying it to form a magnetic layer.
Preferably, the magnetic paint containing the hexagonal system ferrite powder is magnetically orientated by applying a magnetic field in a vertical direction to the magnetic layer after it is coated on the substrate, whereby a magnetic easy axis is readily orientated in the vertical direction and the magnetic layer has good surface smoothness.
The binder resin may be a conventional binder resin such as vinyl chloride/vinyl acetate copolymers, polyvinyl butyral resins, cellulose resins, polyurethane resins, isocyanate compounds and radiation-curable resins.
The organic solvent may be a conventional organic solvent such as toluene, methyl ethyl ketone, methyl isobutyl ketone, cyclohexanone, tetrahydrofuran, ethyl acetate, and mixtures thereof.
The magnetic paint may incorporate various conventional additives such as a dispersant, lubricant, abrasive or antistatic agent.
The present invention provides the magnetic recording medium which suffers from no demagnetization by cooling and less demagnetization by heating, and has good storage property.
PREFERRED EMBODIMENTS
The present invention will be hereinafter explained further in detail by following examples, wherein parts are by weight unless otherwise indicated.
EXAMPLE 1
______________________________________BaCl.sub.2.2H.sub.2 O 21.3 gFeCl.sub.3.6H.sub.2 O 216 gCoCl.sub.2.6H.sub.2 O 19.6 gTiCl.sub.4 31 g______________________________________
The above components were dissolved in one liter of water and mixed with a 1N aqueous solution of sodium hydroxide to prepare a precipitate. The precipitate was hydrothermally reacted at 300° C. for 2 hours in an autoclave. A resultant reaction product was washed with water, filtered and dried, and then thermally treated in the air at 500° C. for 4 hours to prepare a hexagonal Ba ferrite powder, which is expressed by the formula (I) in which A is Ba, M 2+ is Co 2+ , M 4+ is Ti 4+ , n is 6, x+y is 0.23 and x/y is 0.5 (thus x is 0.0766 and y is 0.1533). A coercive force was 770 Oe, a saturation magnetization was 52 emu/g and an average length along major axis was 0.008 μm.
The magnetic paint was prepared by mixing the resultant ferrite powder with the following components for three days in a ball mill:
______________________________________Hexagonal Ba ferrite powder 1,000 partsVinyl chloride/vinyl acetate/vinyl 137.5 partsalcohol copolymer(VAGH, a trade name of U.C.C., U.S.A.)Polyurethane resin 87.5 parts(Pandex T5201, a trade name ofDainippon Ink Chemical Co., Japan)Trifunctional low molecular weight 25 partsisocyanate compound(Colonate L, a trade name of NipponPolyurethane Ind., Japan)Cr.sub.2 O.sub.3 powder 15 partsLauric acid 20 partsLiquid paraffin 2 partsMethyl isobutyl ketone 800 partsToluene 800 parts______________________________________
With applying a magnetic field of 3,000 Oe in the vertical direction, the magnetic paint was coated on a substrate of a polyester film having a thickness of 12 μm and dried to form a magnetic layer having a thickness of 4 μm. Then, the coated substrate was subjected to a smoothing treatment and cut into a desired width to prepare a magnetic tape of the present invention. A temperature dependency of the coercive force in the magnetic tape was determined and is as shown in FIG. 1. The coercive force was minimum at 10° C.
EXAMPLE 2
In the same manner as in Example 1 but using 25 g of CoCl 2 ·6H 2 O and 26.8 g of TiCl 4 in the preparation of the hexagonal Ba ferrite powder, the hexagonal Ba ferrite powder was obtained, which is expressed by the formula (I) in which A is Ba, M 2+ is Co 2+ , M 4+ is Ti 4+ , n is 6, x+y is 0.23 and x/y is 0.75 (thus x is 0.0986 and y is 0.1314). It had the coercive force of 550 Oe, the saturation magnetization of 51 emu/g and the average length along major axis of 0.08 μm.
In the same manner as in Example 1, a magnetic tape of the present invention was prepared by using this ferrite powder. The temperature dependency of the coercive force was determined. It was almost the same as the dependency in Example 1 except that the coercive force curve of FIG. 1 is shifted to the direction of lower temperature so that the coercive force is minimum at -16° C.
COMPARATIVE EXAMPLE 1
In the same manner as in Example 1 but using 30.3 g of CoCl 2 ·6H 2 O and 24 g of TiCl 4 in the preparation of the hexagonal Ba ferrite powder, the hexagonal Ba ferrite powder was obtained. The powder is expressed by the formula (I) in which A is Ba, M 2+ is Co 2+ , M 4+ is Ti 4+ , n is 6, x+y is 0.23 and x/y is 1.0 (thus x is 0.115 and y is 0.115), and it had the coercive force of 630 Oe, the saturation magnetization of 56 emu/g and the average length along major axis of 0.09 μm.
In the same manner as in Example 1, a magnetic tape for comparison was prepared by using this ferrite powder. The dependency of the coercive force on the temperature was determined, and it was different from that in Example 1 such that the coercive force curve of FIG. 1 is greatly shifted to the direction of lower temperature and the coercive force is minimum at -130° C.
COMPARATIVE EXAMPLE 2
In the same manner as in Example 1 but using 5.4 g of CoCl 2 ·6H 2 O and 42.3 g of TiCl 4 , the hexagonal Ba ferrite powder was obtained. The powder is expressed by the formula (I) in which A is Ba, M 2+ is Co 2+ , M 4+ is Ti 4+ , n is 6, x+y is 0.23 and x/y is 0.10 (thus x is 0.021 and y is 0.209) and had the coercive force of 500 Oe, the saturation magnetization of 51.5 emu/g and the average major axis length of 0.09 μm.
In the same manner as Example 1, a magnetic tape for comparison was prepared by using this ferrite powder. The dependency of the coercive force on the temperature was determined, and it was different from that in Example 1 such that the coercive force curve of FIG. 1 is greatly shifted to the direction of higher temperature and the coercive force is minimum at 130° C.
In each magnetic tape of Examples 1 and 2 and Comparative Examples 1 and 2, decrease of residual magnetic flux density was determined when the tape was stored at the temperature of -20°, 0° or 60° C. for 2 hours. The decrease of residual magnetic flux density (%) and the coercive force at 20° C. are shown in Table 1.
TABLE 1______________________________________ Coercive force Decrease of residualExample at 20° C. magnetic flux density (%)No. (Oe) -20° C. 0° C., 60° C.______________________________________1 780 1.2 0.8 2.22 590 3.5 1.8 2.5Comp. 1 650 23.5 11.5 0.9Comp. 2 550 1.0 1.4 8.5______________________________________
As apparent from the results of Table 1, the magnetic tape of the present invention suffers from no demagnetization by cooling, which is found in the conventional tape (Comparative Example 1) and less demagnetization by heating, and has better storage property.
The invention being thus described, it will be obvious that the same may be varied in many ways, Such variations are not to be regarded as a departure from the spirit and scope of the present 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.
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A magnetic recording medium which comprises a substrate and a magnetic layer comprising hexagonal system ferrite powder of the formula:
AO·n{[Fe.sub.1-(x+y) ·M.sup.2+.sub.x
·M 4+ y ] 2 O 3 } (I)
wherein,
A is at least one metal selected from the group consisting of Ba, Sr, Pb and Ca,
M 2+ is at least one divalent metal ion selected from the group consisting of Mn, Co, Ni, Cu, Zn and Mg,
M 4+ is at least one tetravalent metal ion selected from the group consisting of Ti, Zr, Sn, Ge, V and Nb,
n is a number of 3 to 8,
x and y are such numbers that x+y is from 0.02 to 0.3 and x/y is from 0.2 to 0.8.,
and which has a temperature dependency such that the coercive force of the magnetic layer is at a minimum in the temperature range of -20° to 50° C. and has a higher coercive force outside said temperature range
has good storage property.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority pursuant to 35 U.S.C. Section 120 from U.S. patent application Ser. No. 11/079,984 which is a continuation of U.S. patent application Ser. No. 10/886,345 filed Jul. 7, 2004 issued Apr. 12, 2005 as U.S. Pat. No. 6,879,052 which is a divisional of U.S. patent application Ser. No. 10/298,074 filed Nov. 15, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] In general, this invention relates to a system for providing electrical power. More specifically, this invention is directed to a system particularly adapted to provide reliable electrical power for the operation of a remote telecommunications facility.
[0004] Although it may be utilized in numerous applications, this invention is specifically adapted to provide power for the continuous operation of a remote telecommnunications facility. With its core technology substantially composed of digital components, the telecommunications industry is heavily dependent on the continued supply of reliable electrical power. The critical nature of the functions performed by remote telecommunications facilities further emphasizes the need for a dependable power supply.
[0005] Most telecommunications facilities rely on a commercial power utility for electrical power and employ traditional devices, such as a transformer and switchgear, to safely receive and use the electrical power. To insure the facility's power supply is not interrupted, such as in the case of a black-out or other disturbance in the commercial power system, many telecommunications facilities have a system for providing backup power. Although various designs are used, many backup systems employ a diesel generator and an array of batteries. If power from the commercial utility is lost, the diesel generator takes over to supply power, and the battery array insures that power is maintained during the time it takes to switch from utility-supplied power to generator-supplied power. If the generator also fails, such as due to a mechanical malfunction or to the depletion of its fuel source, then the battery array is able to provide power for an additional period of time.
[0006] There are several disadvantages inherent in the current manner in which power is supplied to telecommunications facilities. First, the cost of local electrical utility service has risen dramatically in recent years and, by all accounts, will continue to rise. Thus, the cost of local electrical utility power is a large component of the facility's overall power expenses. Next, as the facility's power demands have increased, the number of batteries required to provide an adequate amount of power for a reasonable period of time has also increased. Clearly, the component cost of the system increases with the greater number of batteries required. In addition, the greater number of batteries required has significantly increased the space required to house the backup system, which has increased the spacial cost of the systems. Finally, it is known that generators suffer from certain reliability problems, such as failing to start when needed because of disuse or failed maintenance. Therefore, the reliability of the backup systems could be improved.
[0007] The power system of the present invention overcomes these disadvantages by providing reliable electrical power that is not initially dependent on a commercial electrical utility and that does not employ an array of batteries. The system, therefore, is more cost efficient and requires less space than the present manner of providing power to facilities. The invention employs redundant sources of power, and thus, is uninterruptible. Also, the system employs power generating components that have less of an impact on the environment than the current manner in which power is supplied. Moreover, the system may be constructed at a manufacturing site and then moved to the facility. Thus, the system of the present invention provides power to a telecommunications facility in a manner that is less expensive, that requires less space, that is movable, and that is environmentally friendly.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention includes a power system that is designed to provide reliable electrical power to a facility, and specifically to a telecommunications facility. The system includes a number of microturbine generators adapted to provide AC power. The system is configured so that the microturbine generators are fueled initially by natural gas supplied by a commercial utility. In the event the natural gas supply fails, the system includes a propane storage tank to provide fuel to the microturbine generators. The system also has an array of rectifiers to convert the AC power from the microturbine generator to DC power. If both of the microturbine generators' fuel sources fail or become exhausted, power is supplied to the rectifiers by a commercial electrical utility, and the system includes components to receive the utility-supplied electricity. The system also includes a number of hydrogen-powered proton exchange membranes that are operable to supply DC power directly to the facility if both the microturbine generators and the electrical utility fail. Finally, the system includes a number of super capacitors that are operable to maintain power during the time required to change between power sources.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0009] The present invention is described in detail below with reference to the attached figure, wherein:
[0010] FIG. 1 is a schematic diagram of the present invention without the sensing/control mechanism.
[0011] FIG. 2 is a functional block diagram of the major components of the present invention; and
[0012] FIG. 3 is a block diagram showing the physical relationship of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention includes both a system and a method for providing reliable electrical power to a facility, and specifically to a telecommunications facility. The system provides redundant sources of electrical power including a number of microturbine generators and a number of proton exchange membranes (PEMs). The system also includes a number of capacitors to provide power during the time it takes to switch between power sources. By employing these components, the system avoids the need for an array of batteries and is more cost efficient than the current method for providing power to telecommunications facilities.
[0014] The present invention is best understood in connection with the schematic diagram of FIG. 1-3 . In FIG. 1 , the power system of the present invention initially comprises a number of microturbine generators 10 . A turbine includes a rotary engine actuated by the reaction or impulse or both of a current of fluid, such as air or steam, subject to pressure and an electrical generator that utilizes the rotation of the engine to produce electrical power. Microturbine generators are a recently developed technology and have not been employed to provide power to a telecommunications facility. A microturbine is smaller and more compact than more common turbines and creates a lower amount of harmful emissions than both more common turbines and diesel generators. A microturbine generator includes a system for receiving fuel, a microturbine for converting the fuel received to electrical power and a digital power controller. Thus, a microturbine generator is able to utilize a fuel source such as natural gas or propane to produce electrical power. One microturbine generator that is suitable for the present invention is the Capstone 60 MicroTurbine™ system produced by the Capstone Turbine Corporation of Chatsworth, Calif. As is understood by those in the art, the number of microturbine generators used in the inventive system depends on the amount of power required by the destination facility.
[0015] The present invention is designed to provide fuel from two different sources to microturbine generators 10 . Initially, microturbine generators 10 are fueled by natural gas. The natural gas is received in primary fuel valve 20 which is coupled to primary fuel pipe or line 30 . Pipe 30 is also coupled to a series of valves 40 , and each of valves 40 is also coupled to an input of a corresponding mixing box 50 . The output of mixing boxes 50 is coupled to the input of one of microturbine generators 10 . Microturbine generators 10 may also be powered by propane stored in a local storage tank 60 . The propane is received through backup fuel valve 70 which is coupled to backup fuel pipe or line 80 . Pipe 80 is also coupled to a series of valves 90 , and each of valves 90 is coupled to an input of mixing boxes 50 . Mixing boxes 50 is operable to combine fuel received with any necessary additional components and thereafter provide appropriate amounts of fuel to microturbine generators 10 . Mixing boxes 50 are capable of receiving and responding to a control signal by at least opening or closing lines. In addition, valves 20 , 40 , 70 and 90 are also capable of receiving and responding to a control signal by at least opening and closing.
[0016] Microturbine generators 10 utilize the natural gas or propane fuel to produce AC electrical power. The output electrical current from each microturbine generator 10 is coupled to one end of a circuit breaker 100 in order to protect the circuit such as, for example, if microturbine generator 10 causes a power surge. The opposite end of circuit breakers 100 is coupled to a bus line 110 that is also coupled to switch 120 . Bus line 130 is coupled to the output of switch 120 and to a number of rectifiers 140 . As is known, a rectifier is capable of receiving an AC input and rectifying or converting that input to produce a DC output. Thus, rectifiers 140 convert the microturbine-produced AC power to DC power. The output of rectifiers 140 is coupled to bus line 150 which is connected to the power distribution unit 160 in the destination facility. Power distribution unit 160 contains connections into the telecommunications facility's power lines, and/or provides connections to the various telecommunications equipment. Power distribution unit 160 may also contain additional circuit breakers or other power switch gear or safety devices and/or circuits, including circuits to limit the voltage or current provided to the facility's power lines, and monitoring/measuring equipment. A number of super capacitors 170 are also connected to bus line 150 .
[0017] The system of the present invention is also capable of receiving power from a commercial utility. Utility-supplied power is received on bus line 180 , and a connection to ground is provided through line 190 . Bus line 180 is connected to one side of switch 200 , and the other side of switch 200 is coupled to the primary side of transformer 210 . As is known, a transformer is capable of receiving an input signal on its primary side and producing a corresponding signal on its secondary side that is electronically isolated from the input signal. The secondary side of transformer 210 is coupled to one side of a main circuit breaker 220 . The opposite side of main circuit breaker 220 is coupled to one side of a number of circuit breakers 230 . The opposite side of one of the circuit breakers 230 is connected to bus line 240 ; the remaining circuit breakers 230 are available to provide electrical power for additional applications or systems. Bus line 240 is also connected to an input of switch 120 .
[0018] The power system of the present invention also includes a number of proton exchange membrane fuel cell modules (PEMs) 250 . A PEM is a device that is capable of converting dry gaseous hydrogen fuel and oxygen in a non-combustive electrochemical reaction to generate DC electrical power. Because the only by-products of this reaction are heat and water, a PEM is friendly to the environment and may be used indoors and in other locations where it is not possible to use a conventional internal combustion engine. In addition, unlike a battery, a PEM is capable of providing electrical power for as long as fuel is supplied to the unit. One PEM that is suitable for the present invention is the Nexa™ power module manufactured by Ballard Power Systems Inc. of Burnaby, British Columbia, Canada. As with microturbine generators 10 , the number of PEMs 250 required is dependent on the amount of power required by the destination facility.
[0019] Hydrogen fuel is supplied to the PEMs 250 from a number of storage tanks 260 located in a vault 270 . Each of the storage tanks 260 is coupled to a valve 280 . Each of valves 280 is coupled to a valve 290 which is also coupled to a pipe 300 . Thereafter, pipe 300 is coupled to a series of valves 310 , and each of valves 310 is coupled to one of the PEMs 250 . The output of the PEMs 250 is connected between bus line 150 and a circuit breaker 320 . As stated above, super capacitors 170 and the power distribution unit 160 of the facility are also connected to bus line 150 . The other side of circuit breakers 320 is connected to a bus line 330 . There are two switches connected to bus line 330 . Switch 340 is coupled to bus line 330 on one side and bus line 150 on the other side. Switch 350 is coupled to bus line 330 on one side and bus line 360 on the other side. Unlike bus line 150 , bus line 360 is only connected to power distribution unit 160 of the facility.
[0020] The power system of the present invention also comprises a number of sensing and control mechanisms (not expressly shown) for determining which fuel source to activate and which power source to engage. As is known, the sensing mechanisms may be separate devices or may be integral to the valves, bus lines, and/or devices being monitored. Likewise, the control mechanism may be a separate device, such as a programmable logic controller, or may be part of one of the components already described, such as the microturbine generators 10 . It is also possible that the sensing and control mechanisms may be combined into a solitary mechanism that may be a stand-alone unit or may be combined with one of the components already described.
[0021] The operation of the power system may be understood by referring to FIG. 2 . It should be noted that the present invention is represented in FIG. 2 by functional blocks. Thus, sensing/control mechanism 370 is shown as one unit when in fact the sensing and control devices actually may be several devices as discussed previously. Of course, all of the sensing and control devices actually may be placed together in a separate unit, such as a programmable logic controller, as shown in FIG. 2 .
[0022] In operation, the sensing/control mechanism 370 initially causes valves 380 (which include valves 40 and 90 shown in FIG. 1 ) to allow natural gas to flow from the utility source to the microturbine generators 390 and to prevent the flow of propane to microturbine generators 390 . Sensing/control mechanism 370 also initiates operation of the microturbine generators 390 . In addition, sensing/control mechanism 370 also causes valves 400 (which include valves 310 shown in FIG. 1 ) to prevent the flow of hydrogen to the PEMs 410 and causes the PEMs 410 to remain off. In this manner, microturbine generators 390 produce AC power using utility-supplied natural gas. The AC current produced by the microturbine generators passes through switch 420 to rectifiers 430 where it is converted to DC current. Thereafter, the DC current from rectifiers 430 is provided to the telecommunications facility and to super capacitors 440 . As is well known, when they first receive DC current, super capacitors 440 charge to the level of the DC power provided.
[0023] If sensing/control mechanism 370 determines that there is an interruption in the utility-supplied natural gas, then it will cause valves 380 to prevent the flow of natural gas and allow the flow of hydrogen to microturbine generators 390 . Switch 420 remains in the same position as before and valves 400 continue to prevent the flow of hydrogen to PEMs 410 . In this configuration, microturbine generators 390 continue to generate AC power but now their fuel is propane.
[0024] If the sensing/control mechanism 370 determines that both fuel sources for microturbine generators 390 have failed or that there is some other disturbance in the microturbine-supplied power which causes that power to become inadequate, then sensing/control mechanism 370 will cause valves 380 to close and deactivate the microturbine generators 390 . Sensing/control mechanism 370 will set switch 420 so that rectifiers 430 receive AC power from the electric utility. In addition, sensing/control mechanism 370 will keep valves 400 closed and PEMs 410 deactivated.
[0025] If sensing/control mechanism 370 determines that the electric utility has failed or the power it supplies has become inadequate and the microturbine generators 390 remain deactivated, such as due to a lack of fuel or a malfunction, then sensing/control mechanism 370 will cause valves 400 to open which allows hydrogen to flow to PEMs 410 . Thereafter, the control mechanism will activate PEMs 410 . In this manner the PEMs 410 provides DC power to the telecommunications facility and to super capacitors 440 .
[0026] In each of the above scenarios, super capacitors 440 provide electrical power during the time it takes for the control mechanism to switch from one power source to another. Thus, super capacitor 440 must have a discharge time greater than the longest time required to switch between power sources. One super capacitor that is suitable for this invention is manufactured by Maxwell Technologies located in San Diego, Calif.
[0027] Referring now to FIG. 3 , significant portions of the present invention may be enclosed in a modular, weatherproof container, indicated by the numeral 450 , that is transportable by truck or rail. For example, all of the components shown in FIG. 1 , except tank 60 and vault 270 with the components contained therein, may be pre-assembled and pre-wired with the sensing/control mechanism(s) and then placed in container 450 before being shipped to a facility. Once at the facility, propane storage tank 460 and hydrogen storage vault 470 are provided and coupled to container 450 . Once utility-supplied natural gas and electricity lines have been coupled to container 450 and the output of container 450 is coupled to the telecommunications facility 480 , then the unit may be activated.
[0028] As discussed, the power system described above initially employs microturbine generators to provide electrical power for a telecommunications facility. The microturbine generators are compact, efficient (both in terms of space and fuel) and reliable. By relying on microturbine generators as the main source of power, the system avoids both the reliability problems and environmental hazards inherent in internal combustion generators and the costs and environmental concerns associated with commercial electrical power. The power system also provides redundant sources of power, specifically from a commercial electrical utility and a number of proton exchange membranes, and therefore is uninterruptible. Finally, the system provides a number of super capacitors to provide electrical power during the time it takes to switch between power sources. By employing super capacitors and proton exchange membranes, the power system avoids the use of batteries thereby saving significant cost and space.
[0029] It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, all matter shown in the accompanying drawings or described hereinabove is to be interpreted as illustrative and not limiting. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description.
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Disclosed is a method of supplying DC power to equipment using proton exchange membranes (PEMs). PEMs run on hydrogen to produce DC electrical power. In the disclosed embodiment these PEMs are used as an alternative source of power to AC sources. One of these other sources is generated by an array of gas turbines. Another source is provided by a commercial utility. AC from these sources is converted using rectifiers. Capacitors are used to bridge when switching between energy sources.
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TECHNICAL FIELD
[0001] The present invention relates to a setting device and the like that set an information processing device to a communication-enabled state.
BACKGROUND ART
[0002] Examples of systems that are capable of estimating a communication bandwidth in a communication network include systems described in PTL 1 to PTL 6.
[0003] PTL 1 discloses a network bandwidth measurement system that estimates a communication bandwidth based on a sequence of a plurality of packets with gradually increasing size or gradually decreasing size. For convenience of explanation, a sequence of a plurality of packets with gradually increasing size or gradually decreasing size will be hereinafter referred to as a “packet train”.
[0004] The network bandwidth measurement system includes a packet generation unit, a packet transmission unit, a reception interval measuring unit and a bandwidth computing unit. The packet generation unit generates a sequence of a plurality of packets with gradually increasing size or gradually decreasing size. The packet transmission unit transmits the plurality of generated packets at predetermined transmission intervals. The reception interval measuring unit sequentially receives each packet and measures reception intervals each representing an interval between timings at which packets are received. The bandwidth computing unit estimates a communication bandwidth in a communication network on the base of the largest packet size among packets whose reception interval is equal to their transmission interval.
[0005] PTL 2 discloses a usable bandwidth measurement system that estimates a communication bandwidth on the base of time needed to transmit and receive packets with increasing size by a fixed common difference. The usable bandwidth measurement system has the function of changing packet size on the base of the estimated communication bandwidth.
[0006] PTL 3 discloses a flow rate prediction device that generates a stochastic process model for estimating communication throughput based on the communication throughput of a communication network, for example. The flow rate prediction device determines, based on communication throughput changing over time, whether the communication throughput is in a steady state or non-steady state. The flow rate prediction device then selects a stochastic process model for estimating the communication throughput based on the determination result and computes parameters of the selected stochastic process model.
[0007] PTL 4 discloses a parameter estimating device that determines, based on communication throughputs acquired before a first time point, a probability density function for estimating a communication throughput at a second time point.
[0008] PTL 5 discloses a degradation avoiding method that identifies, based on transmission/reception qualities of a plurality of media, a medium with degraded quality of transmission/reception processing and determines whether to reduce the rate of communication flow on the medium or not. The degradation avoiding method identifies a medium with degraded quality of transmission/reception processing in accordance with correlation between priorities of a plurality of media and the degradation degree of transmission/reception quality of the media and reduces the rate of communication flow on the media correlated to the identified medium.
[0009] PTL 6 discloses a delay variation prediction device, relating to a packet, that identifies an ARCH type model on the base of a delay time difference that changes over time and estimates jitter on the base of the identified ARCH type model. ARCH type modeling is a well-known method for precisely modeling a transition of volatility in the fields of financial engineering and econometrics. The delay variation prediction device estimates changes in jitter as statistically estimated quantities concerning time series representing delay time differences in accordance with the ARCH model. The delay variation prediction device computes parameters of an ARCH type model on the base of delay time differences. ARCH is abbreviation of Autoregressive conditional heteroscedasticity.
CITATION LIST
Patent Literature
[0010] PTL 1: Japanese Unexamined Patent Application Publication No. 2011-142622
[0011] PTL 2: International Publication No. WO 2011/132783
[0012] PTL 3: International Publication No. WO 2014/007166
[0013] PTL 4: International Publication No. WO 2013/008387
[0014] PTL 5: Japanese Patent No. 5239791
[0015] PTL 6: Japanese Unexamined Patent Application Publication No. 2014-135685
SUMMARY OF INVENTION
Technical Problem
[0016] Communication facility of an information processing device (terminal) can be, for example, in a first state representing a state with higher (better) throughput than a predetermined throughput or a second state representing a state with lower (poorer) throughput than the predetermined throughput. For example, the first state represents an active state in which processing relating to communication (communication processing) is enabled. The second state represents a sleep state in which communication processing is disabled, for example. When the communication facility is in the second state, communication information (communication data) destined to the communication facility is temporarily stored in a router, a wireless base station, or the like in a communication network. The information processing device, for example, checks whether or not communication information is stored in the wireless base station or the like at each predetermined timing. If the communication information is stored, the information processing device sets the communication facility to the first state. Then, the communication facility reads the communication information stored in the wireless base station or the like. The communication facility performs processing relating to the read communication information.
[0017] The network bandwidth measurement system disclosed in PTL 1 cannot necessarily precisely estimate a communication bandwidth relating to the communication network as described above. This is because the communication facility collectively receives communication information stored while the communication facility is in the second state and therefore parameters (for example timing of reception) concerning the communication information differ from parameters concerning communication information in the first state.
[0018] For example, even when a first information processing device sequentially transmits signals (packets) to a second information processing device, the communication facility in the second information processing device collectively receives the signals at once after the communication device has been in the second state. Consequently, the communication facility of the second information processing device cannot precisely estimate a communication bandwidth when the communication facility estimates the communication bandwidth on the base of the timing at which a signal is received, for example.
[0019] Therefore, a main object of the present invention is to provide a setting device and the like that enable precise estimation of a communication bandwidth.
Solution to Problem
[0020] In order to achieve the aforementioned object, as an aspect of the present invention, a setting device including:
[0021] transmission means for transmitting, in accordance with a first timing at which a first information processing device transmits a first signal for measuring communication bandwidth of a communication network to a second information processing device, a setting signal for setting communication means of the second information processing device into a communication-enabled state to the second information processing device.
[0022] In addition, as another aspect of the present invention, a setting method including:
[0023] transmitting, in accordance with a first timing at which a first information processing device transmits a first signal for measuring communication bandwidth of a communication network to a second information processing device, a setting signal for setting communication means of the second information processing device into a communication-enabled state to the second information processing device.
[0024] In addition, as another aspect of the present invention, a setting program making a computer achieve including:
[0025] a transmission function for transmitting, in accordance with a first timing at which a first information processing device transmits a first signal for measuring communication bandwidth of a communication network to a second information processing device, a setting signal for setting communication means of the second information processing device into communication-enabled state to the second information processing device.
[0026] Furthermore, the object is also realized by an associated setting program, and a computer-readable recording medium which records the program.
Advantageous Effects of Invention
[0027] A setting device and the like according to the present invention enable precise estimation of a communication bandwidth.
BRIEF DESCRIPTION OF DRAWINGS
[0028] FIG. 1 is a block diagram illustrating a configuration of a setting device according to a first example embodiment of the present invention.
[0029] FIG. 2 is a flowchart illustrating a process flow in the setting device according to the first example embodiment.
[0030] FIG. 3 is a sequence diagram illustrating processing performed by the setting device, a first information processing device, and a second information processing device.
[0031] FIG. 4 is a diagram conceptually illustrating example states of a communication unit.
[0032] FIG. 5 is a block diagram illustrating a configuration of a communication system according to the first example embodiment.
[0033] FIG. 6 is a block diagram illustrating an example configuration of a client device according to the first example embodiment.
[0034] FIG. 7 is a block diagram illustrating an example configuration of a server device according to the first example embodiment.
[0035] FIG. 8 is a sequence diagram illustrating an example of a process flow in the server device and a second information processing device according to the first example embodiment.
[0036] FIG. 9 is a block diagram illustrating a configuration of a setting device according to a second example embodiment of the present invention.
[0037] FIG. 10 is a flowchart illustrating a process flow in the setting device according to the second example embodiment.
[0038] FIG. 11 is a sequence diagram illustrating a process performed by the setting device, a first information processing device, and a second information processing device according to the second example embodiment.
[0039] FIG. 12 is a block diagram illustrating a configuration of a setting device according to a third example embodiment of the present invention.
[0040] FIG. 13 is a flowchart illustrating a process flow in the setting device according to the third example embodiment.
[0041] FIG. 14 is a block diagram schematically illustrating a hardware configuration of a calculation processing apparatus capable of realizing the setting devices according to each example embodiment.
DESCRIPTION OF EMBODIMENTS
[0042] Next, example embodiments of the present invention will now be described in detail with reference to the drawings.
First Example Embodiment
[0043] A configuration of a setting device 101 according to a first example embodiment of the present invention will be described in detail with reference to FIG. 1 . FIG. 1 is a block diagram illustrating a configuration of a setting device 101 according to the first example embodiment of the present invention.
[0044] The setting device 101 according to the first example embodiment includes a transmission unit 102 .
[0045] The setting device 101 , a first information processing device 401 and a second information processing device 402 are capable of transmitting and receiving information to and from one another via a communication network 403 . The second information processing device 402 includes a communication control unit 406 and a communication unit 407 . The second information processing device 402 may include a bandwidth estimation device 404 .
[0046] The bandwidth estimation device 404 may be a device separate from the second information processing device 402 . For convenience of explanation, it is assumed hereinafter that the second information processing device 402 includes the bandwidth estimation device 404 .
[0047] When the first information processing device 401 (for example a server device) and the second information processing device 402 (for example a client device or terminal) start to communicate with each other, the first information processing device 401 and the second information processing device 402 negotiate with each other. The negotiation is a processing of determining parameters for communication, before establishing communication connection, by exchanging the parameters such as a transmission rate, a communication protocol and parameters for estimating a communication bandwidth
[0048] Processing performed by the setting device 101 , the first information processing device 401 and the second information processing device 402 will be described with reference to FIG. 3 . FIG. 3 is a sequence diagram illustrating the process performed by the setting device 101 , the first information processing device 401 , and the second information processing device 402 .
[0049] The second information processing device 402 transmits, to the first information processing device 401 , a request for setting time intervals between transmission of a plurality of signals (hereinafter referred to as the “first signals”), such as a packet train shown in the Background Art, used for estimating a communication bandwidth (step S 202 ).
[0050] The first information processing device 401 receives the request (step S 203 ). The first information processing device 401 then determines the timing (for example a K-th timing, which will be described later) of transmitting a K-th first signal (where K represents a natural number between 1, inclusive, and N, inclusive) on the base of time intervals (transmission intervals) included in the request (step S 204 ). The first information processing device 401 transmits information indicating the determined timing (timing information) to the setting device 101 (step S 205 ). The timing information may be information indicating a time interval between the K-th timing and the (K+1)-th timing or information representing the K-th timing, for example.
[0051] Processing for determining the timing will be described by using an example in which the first signals, that is transmitted and received for estimating a communication bandwidth, are packets in a packet train. The packets in a packet train are, for example, sent out at transmission intervals determined during negotiation. The transmission intervals represent, for example, a time interval (period) between a timing for transmitting a J-th bit of a packet (where J represents a natural number) and a timing for transmitting the J-th bit of the next packet. The first signal is not limited to the example described above but may be any signal that the first information processing device 401 transmits to the second information processing device 402 .
[0052] A communication bandwidth is estimated on the base of the timing at which the second information processing device 402 receives the first signal.
[0053] The setting device 101 receives the timing information (step S 206 ). The transmission unit 102 transmits, to the second information processing device 402 , a setting signal for setting the communication unit 407 to a communication-enabled state (i.e. a first state, which will be described later), on the base of timing (or time intervals) included in the received timing information (step S 207 ).
[0054] For example, the transmission unit 102 may transmit the setting signal at the time intervals based on the received timing information when the time interval between the K-th timing and the (K+1)-th timing is constant (or substantially constant). As described in the descriptions of example embodiments given later, the transmission unit 102 may transmit the setting signal when a predetermined condition is satisfied. For example, a predetermined interval may be the time that elapses between the timing of the last communication processing performed by the communication unit 407 in an active state in the second information processing device 402 and the timing at which the communication unit 407 is set into a sleep state.
[0055] In each example embodiment of the present invention, the active state represents a first state representing a state of higher (better) throughput than a predetermined throughput. The sleep state represents a second state representing a state of lower (poorer) throughput than the predetermined throughput. In the process illustrated in step S 207 , the transmission unit 102 may read the K-th timing from the received timing information and may transmit the setting signal at a timing before the read K-th timing and close to the K-th timing.
[0056] Referring to FIG. 2 , in the processing relating to step S 207 ( FIG. 3 ) described above, the transmission unit 102 transmits the setting signal to the second information processing device 402 in accordance with the K-th timing (step S 110 ). FIG. 2 is a flowchart illustrating a process flow in the setting device 101 according to the first example embodiment.
[0057] On the other hand, the first information processing device 401 transmits a first signal to the second information processing device 402 when the determined timing is reached after the establishment of a communication connection (step S 210 ).
[0058] The communication control unit 406 in the second information processing device 402 receives the setting signal transmitted from the setting device 101 (step S 208 ) and sets the communication unit 407 in the second information processing device 402 to the first state (step S 209 ). Then, the communication unit 407 receives the first signal in response to the arrival of the first signal from the first information processing device 401 (step S 211 ).
[0059] The communication unit 407 in the second information processing device 402 which receives a setting signal transmitted from the setting device 101 will be described with reference to FIG. 4 . FIG. 4 is a diagram conceptually illustrating example states of the communication unit 407 . For example, the communication unit 407 can be in a first state or in a second state. The communication unit 407 can perform communication processing when the communication unit 407 is in the first state. The communication unit 407 in the first state is set to the second state in case that communication processing has not been performed for a certain long period of time.
[0060] On the other hand, when the communication unit 407 is in the second state, communication information destined to the communication unit is temporarily stored in a router, a wireless base station, or the like in the communication network. The second information processing device 402 checks whether or not communication information is stored in the wireless base station or the like, for example, at a given timing. If the communication information is stored, the second information processing device 402 sets the communication unit 407 to the first state.
[0061] The process performed when the communication unit 407 in the second information processing device 402 is in the second state will be described in further detail. When the communication unit 407 is in the second state, communication information (for example, information transmitted and received) relating to the second information processing device 402 is stored in a router, a wireless base station, or the like, for example, in the communication network 403 . During the second state in the communication unit 407 , the communication control unit 406 monitors signals transmitted from the wireless base station or the like at each predetermined interval, for example, to see whether or not there is communication information. When the communication control unit 406 determines that there is communication information in the wireless base station or the like, the communication control unit 406 sets the communication unit 407 to the first state. During the first state in the communication unit 407 , the communication unit 407 receives the communication information from the wireless base station or the like and performs communication processing relating to the received communication information. In this case, the communication unit 407 collectively receives the communication information stored in the wireless base station or the like at once.
[0062] For example, in the case of LTE defined in 3GPP, the first state is the RRC Connected and Active state whereas the second state is the RRC Connected and Short DRX state, the Long DRX state, or the RRC Idle state.
[0063] 3GPP is an abbreviation of Third Generation Partnership Project. LTE is an abbreviation of Long Term Evolution. RRC is an abbreviation of Radio Resource Control. DRX is an abbreviation of discontinuous reception.
[0064] Processing subsequent to step 211 will be described next with reference to FIG. 3 . In response to the second information processing device 402 receiving the first signal, the bandwidth estimation device 404 estimates a communication bandwidth relating to the communication network 403 on the base of the first signal (step S 212 ). For example, the communication bandwidth may be estimated in accordance with a procedure disclosed in PTL 1. However, the present invention described using the present example embodiment as an example is not limited to the procedure disclosed in PTL 1. Any procedure with which a communication bandwidth can be estimated on the base of a signal transmitted and received may be used.
[0065] The second information processing device 402 transmits the estimation result of the communication bandwidth to the first information processing device 401 (step S 213 ).
[0066] A timing at which the second information processing device 402 performs process illustrated in step S 213 in response to a K-th first signal will be hereinafter referred to as the “K-th reply timing”.
[0067] The first information processing device 401 receives the estimation result transmitted from the second information processing device 402 (step S 214 ).
[0068] When the (K+1)-th first signal is transmitted, processing similar to the processing performed when the K-th first signal is transmitted is performed. In the following description, the process performed when the (K+1)-th first signal is transmitted will be described with reference to the step numbers used in the description of the process performed when the K-th first signal is transmitted.
[0069] Based on the timing (or time intervals) included in timing information received by the setting device 101 , the transmission unit 102 transmits a setting signal for setting the communication unit 407 to a communication-enabled state to the communication control unit 406 (step S 207 ).
[0070] In response to receiving the setting signal (step S 208 ), the communication control unit 406 in the second information processing device 402 sets the communication unit 407 in the second information processing device 402 to the first state (step S 209 ).
[0071] In response to the arrival of the (K+1)-th timing, the first information processing device 401 transmits a first signal to the second information processing device 402 (step S 210 ).
[0072] In response to the communication unit 407 receiving the first signal after having been set to the first state, the bandwidth estimation device 404 estimates a communication bandwidth relating to the communication network 403 (steps S 209 , S 211 and S 212 ). The second information processing device 402 transmits the estimation result of the communication bandwidth in the bandwidth estimation device 404 to the first information processing device 401 (step S 213 ). The first information processing device 401 receives the estimation result (step S 214 ).
[0073] Advantageous effects of the setting device according to the first example embodiment of the present invention will be described next.
[0074] The setting device 101 according to the present example embodiment can provide an environment that enables precise estimation of a communication bandwidth. This is because, in response to receiving a setting signal, the communication unit 407 in the second information processing device 402 is set to the first state and then receives a first signal.
[0075] The reason that the advantageous effect described above is achieved will be described in detail. In response to arrival of a first signal during the first state in the communication unit 407 , the communication unit 407 in the second information processing device 402 receives the first signal. Accordingly, the timing of arrival of the first signal is precisely measured and therefore, in the setting device 101 according to the present example embodiment, for example, the bandwidth estimation device 404 can precisely estimate a communication bandwidth relating to the communication network 403 .
[0076] Whereas, the first information processing device 401 can possibly transmit the first signal to the communication unit 407 in a period in which the second information processing device 402 is not set to the first state by the setting device 101 according to the present example embodiment and the communication unit 407 is in the second state. In this case, the wireless base station or the like temporarily stores the first signal in itself as described with reference to FIG. 4 . If communication information is stored in the wireless base station or the like, for example, the second information processing device 402 changes the communication unit 407 from the second state to the first state. Then the communication unit 407 collectively receives the communication information including the first signal from the wireless base station or the like at once. Accordingly, the timing of arrival of the first signal is not precisely measured and therefore the bandwidth estimation device 404 cannot precisely estimate a communication bandwidth.
[0077] Further, when the transmission unit 102 transmits a setting signal at a timing before the K-th timing and close to the K-th timing, the setting device 101 according to the present example embodiment has the following advantageous effect. The setting device 101 according to the present example embodiment has the advantageous effect of precisely estimating a communication bandwidth relating to the communication network 403 and, in addition, the advantageous effect of reducing the costs of estimating the communication bandwidth. The costs include power consumption in the communication unit 407 , for example. This is because the period of time between the timing at which the communication unit 407 in the second information processing device 402 is set into the first state and the K-th timing is short. Since the transmission unit 102 transmits the setting signal at the timing before the K-th timing and close to the K-th timing, the communication unit 407 can receive a signal transmitted from the first information processing device 401 around the time when the communication unit 407 has been set into the first state according to the setting signal. Consequently, the period of time between the timing at which the communication unit 407 in the second information processing device 402 is set into the first state and the K-th timing is short.
[0078] The setting device 101 may be a part of a communication system 105 , for example, as illustrated in FIG. 5 . FIG. 5 is a block diagram illustrating a configuration of the communication system 105 according to the first example embodiment.
[0079] The communication system 105 includes the setting device 101 , a control unit 103 , a first information processing device 401 , an estimation unit 104 , a second information processing device 113 , and a communication network 403 . The setting device 101 , the control unit 103 , the first information processing device 401 , the estimation unit 104 , and the second information processing device 113 are capable of communicating with one another via the communication network 403 .
[0080] The estimation unit 104 has functions similar to the bandwidth estimation device 404 described above. The second information processing device 113 has functions similar to the communication control unit 406 and the communication unit 407 in the second information processing device 402 described above. In other words, the second information processing device 113 includes a communication control unit 406 and a communication unit 407 . The control unit 103 controls communication performed via the communication network 403 .
[0081] For example, the communication system 105 may include a decision device (not depicted) that decides to add or remove a control unit 103 that controls communication via the communication network 403 in the communication system 105 in accordance with a estimation result relating to a communication bandwidth. In this case, when the estimated communication bandwidth is smaller (narrower) than a predetermined first value, the decision device decides to add the control unit 103 . On the other hand, when the estimated communication bandwidth is greater (broader) than a predetermined second value, the decision device decides to remove the control unit 103 .
[0082] In another example, a client device 106 may include a setting device 101 as illustrated in FIG. 6 . FIG. 6 is a block diagram illustrating an example configuration of the client device 106 according to the first example embodiment.
[0083] The client device 106 includes a setting device 101 , an estimation unit 104 , and the second information processing device 402 . The client device 106 is capable of transmitting and receiving information to and from a first information processing device 401 via a communication network 403 .
[0084] The client device 106 ( FIG. 6 ) according to the first example embodiment has the advantageous effect of precisely estimating a communication bandwidth relating to the communication network 403 and, in addition, the advantageous effect of providing an environment that enables a communication bandwidth to be precisely estimated with a small amount of communication traffic. This is because a setting signal does not pass through the communication network 403 . Specifically, since the client device 106 has the configuration described above, the process by the setting device 101 for transmitting the setting signal to the second information processing device 402 is performed within the client device 106 . Accordingly, the setting signal arrives at the second information processing device 402 without passing through the communication network 403 . Consequently, in accordance with the configuration of the client device 106 including the setting device 101 and the second information processing device 402 , the amount of communication traffic on the communication network 403 is reduced.
[0085] As an alternative to the processing mode illustrated in FIG. 6 , a configuration of a server device 107 that includes a setting device 101 and processing performed by the server device 107 will be described in detail with reference to FIGS. 7 and 8 . FIG. 7 is a block diagram illustrating an example configuration of the server device 107 according to the first example embodiment. FIG. 8 is a sequence diagram illustrating an example of a flow of processing in the server device 107 and the second information processing device 402 according to the first example embodiment.
[0086] The server device 107 may include the setting device 101 , a first information processing device 401 and an estimation unit 104 .
[0087] The server device 107 is capable of transmitting and receiving information to and from the second information processing device 402 via a communication network 403 .
[0088] As in the process illustrated in step S 202 in FIG. 3 , the first information processing device 401 transmits to the first information processing device 401 a request for setting time intervals at which a first signal is to be transmitted (step S 303 ). Then, the server device 107 receives the request (step S 304 ).
[0089] Then, the first information processing device 401 determines a timing at which a K-th first signal is to be transmitted (where K represents a natural number between 1, inclusive, and N, inclusive) on the base of the time intervals (transmission intervals) included in the request (step S 305 ).
[0090] A transmission unit 102 transmits a setting signal for setting a communication unit 407 to the first state, that is a communication-enabled state, to the second information processing device 402 on the base of the timing (or time intervals) determined by the first information processing device 401 (step S 306 ). In response to receiving the setting signal (step S 307 ), a communication control unit 406 in the second information processing device 402 sets a communication unit (for example a communication unit 407 as illustrated in FIG. 1 ) included in the second information processing device 402 to the first state (step S 308 ).
[0091] In response to the arrival of the determined timing, the first information processing device 401 transmits a first signal to the second information processing device 402 via the communication network 403 (step S 309 ). The second information processing device 402 receives the first signal (step S 310 ) and transmits a second signal responding to the first signal to the first information processing device 401 (step S 311 ).
[0092] The second signal may be for example an acknowledgement (ack) signal indicating that the first signal has been received or may be a signal including information about the timing at which the second information processing device 402 received the first signal.
[0093] The first information processing device 401 receives the second signal transmitted from the second information processing device 402 (step S 312 ). In response to the first information processing device 401 receiving the second signal, the estimation unit 104 estimates a communication bandwidth relating to the communication network 403 on the base of the timing information included in the second signal, for example (step S 313 ).
[0094] Processing similar to the processing performed when the K-th first signal is transmitted is performed when subsequently the (K+1)-th first signal is transmitted. In the following description, the processing performed when the (K+1)-th first signal is transmitted will be described with reference to the step numbers used in the description of the processing performed when the K-th first signal is transmitted.
[0095] The setting device 101 transmits a setting signal to the second information processing device 402 (step S 306 ).
[0096] In response to receiving the setting signal (step S 307 ), the second information processing device 402 sets a communication unit (for example a communication unit 407 as illustrated in FIG. 1 ) in the second information processing device 402 to the first state (step S 308 ).
[0097] The first information processing device 401 transmits a first signal to the communication unit in the second information processing device 402 (step S 309 ). The second information processing device 402 receives the first signal (step S 310 ) and transmits a second signal responding to the first signal to the first information processing device 401 (step S 311 ).
[0098] The first information processing device 401 receives the second signal transmitted from the second information processing device 402 (step S 312 ). In response to the first information processing device 401 receiving the second signal, the estimation unit 104 estimates a communication bandwidth relating to the communication network 403 on the base of timing information included in the second signal, for example (step S 313 ).
[0099] The server device 107 according to the first example embodiment illustrated in FIG. 7 has the advantageous effect of precisely estimating a communication bandwidth relating to the communication network 403 . Further, the server device 107 according to the first example embodiment can provide an environment that enables a communication bandwidth to be precisely estimated even when time measured by the system clock of the server device 107 differs from time measured by the system clock of the second information processing device 402 . The system clock within each device may measure time independently of system clocks of the other devices, for example. This is because the K-th timing and the timing at which the setting signal is transmitted are measured by the system clock of the server device 107 .
[0100] As the server device 107 includes the first information processing device 401 and the setting device 101 , the first information processing device 401 , and the setting device 101 operate on the base of the system clock of the server device 107 . Accordingly, the K-th timing and the timing at which the setting signal is transmitted are measured by the system clock of the server device 107 . Consequently, the setting device 101 can transmit the setting signal properly even when there is a difference between time measured by the system clock of the second information processing device 402 and time measured by the system clock of the first information processing device 401 . Accordingly, the communication facility in the second information processing device 402 receives a signal from the first information processing device 401 within a period in which the communication facility is in the first state. Consequently, the server device 107 according to the present example embodiment can precisely estimate a communication bandwidth even when time measured by the system clock of the first information processing device 401 differs from time measured by the system clock of the second information processing device 402 .
Second Example Embodiment
[0101] Next, a second example embodiment of the present invention based on the above-described first example embodiment will be described.
[0102] Hereinafter, description will be made focusing on characteristic features of the present example embodiment. The same reference numerals are given to the same configurations as those of the above-described first example embodiment, and redundant explanations will be omitted.
[0103] A configuration of a setting device 108 according to a second example embodiment and processing performed by the setting device 108 will be describe with reference to FIGS. 9 to 11 . FIG. 9 is a block diagram illustrating a configuration of the setting device 108 according to the second example embodiment of the present invention. FIG. 10 is a flowchart illustrating a process flow in the setting device 108 according to the second example embodiment. FIG. 11 is a sequence diagram illustrating a process performed by the setting device 108 , a first information processing device 401 , and a second information processing device 402 according to the second example embodiment.
[0104] The setting device 108 according to the second example embodiment includes a determination unit 109 and a transmission unit 110 .
[0105] As seen from FIG. 11 , processing similar to the process illustrated in step S 210 to step S 213 of FIG. 3 is performed. Then, the first information processing device 401 receives an estimation result transmitted from the second information processing device 402 (step S 214 ).
[0106] Then the second information processing device 402 transmits timing information to the setting device 108 via a communication network 403 (step S 215 ). The timing information in this case includes information representing the K-th timing described above and the time while a communication unit 407 is in a first state before transition to a second state (hereinafter referred to as the “first period”). Alternatively, the timing information may further include information representing a second period from the K-th timing to the (K+1)-th timing.
[0107] The first period may be the time between the K-th reply timing at which a signal responding to the K-th first signal is transmitted and the timing at which the communication unit 407 is set into the second state. When the second information processing device 402 performs some processing (hereinafter referred to as the “second processing”) after the K-th reply timing, the second information processing device 402 may set the period between the timing at which the second processing ends and the timing at which the communication unit 407 is set into the second state as the first period. In this case, the second information processing device 402 transmits timing information to the setting device 108 in response to the end of the second processing.
[0108] Then, the setting device 108 performs the process illustrated in step S 216 . The process illustrated in step S 216 will be described in detail with reference to FIG. 10 . The setting device 108 receives timing information. In response to the setting device 108 receiving the timing information, the determination unit 109 determines whether or not the first period is shorter than the second period (step S 102 ).
[0109] When the determination unit 109 determines that the first period is shorter than the second period (YES at step S 102 ), the determination unit 109 transmits a setting signal to the second information processing device 402 in the second period (step S 110 , i.e. step S 216 of FIG. 11 ). When the determination unit 109 determines that the first period is longer than the second period or the length of the first period is equal to the length of the second period (NO at step S 102 ), the determination unit 109 does not perform the process illustrated in step S 110 .
[0110] Processing subsequent to step S 216 will be described with reference to FIG. 11 . In response to receiving the setting signal (step S 217 ), the communication control unit 406 sets the communication unit 407 in the second information processing device 402 to a first state (step S 218 ).
[0111] In response to the arrival of a determined timing, the first information processing device 401 transmits a first signal to the second information processing device 402 (step S 219 ).
[0112] Then, in response to the arrival of the first signal from the first information processing device 401 , the communication unit 407 receives the first signal (step S 220 ). In response to the communication unit 407 in the second information processing device 402 receiving the first signal, a bandwidth estimation device 404 estimates a communication bandwidth relating to the communication network 403 (step S 221 ). The second information processing device 402 transmits the estimation result relating to the estimated communication bandwidth to the first information processing device 401 (step S 222 ).
[0113] The first information processing device 401 receives the estimation result (step S 223 ).
[0114] Advantageous effects of the setting device 108 according to the second example embodiment will be described next.
[0115] The setting device 108 according to the present example embodiment has the advantageous effect of enabling precise estimation of a communication bandwidth. Further, the setting device 108 according to the present example embodiment has the advantageous effect of reducing the amount of communication traffic and the frequency of communications. This is because of reasons 1 and 2:
[0116] (Reason 1) The configuration of the setting device 108 according to the second example embodiment includes a configuration similar to the setting device 101 according to the first example embodiment, and
[0117] (Reason 2) When it is determined that the first period is longer than the second period, the transmission unit 110 does not transmit a setting signal to the second information processing device 402 .
[0118] When the first period is longer than the second period, the communication unit 407 is set to the second state after a third timing. In this case, the communication unit 407 is in the first state at the third timing without having to receiving a setting signal. Therefore, when the first period is longer than the second period, the setting device 108 does not need to transmit a setting signal to the second information processing device 402 . Thus, the setting device 108 according to the present example embodiment has the advantageous effect of reducing the amount of communication traffic and the frequency of communications.
Third Example Embodiment
[0119] Next, a third example embodiment of the present invention based on the above-described first example embodiment will be described.
[0120] Hereinafter, description will be made focusing on characteristic features of the present example embodiment. The same reference numerals are given to the same configurations as those of the above-described first example embodiment, and redundant explanations will be omitted.
[0121] A configuration of a setting device 112 according to a third example embodiment and processing performed by the setting device 112 will be described with reference to FIGS. 12 and 13 . FIG. 12 is a block diagram illustrating a configuration of the setting device 112 according to the third example embodiment of the present invention. FIG. 13 is a flowchart illustrating a processing flow in the setting device 112 according to the third example embodiment.
[0122] The setting device 112 according to the third example embodiment includes an estimation unit 111 , a determination unit 109 and a transmission unit 110 .
[0123] First, the estimation unit 111 estimates a first period on the base of history information 405 in which a K-th timing (where K represents an integer greater than or equal to 1), the (K+1)-th timing and a state (for example a first state or a second state) of the communication unit 407 at the (K+1)-th timing are associated with one another (step S 104 ).
[0124] The history information 405 may not include information about the state of the communication unit 407 , for example. The history information 405 may be information about a state in which a communication facility in a third information processing device is placed when the third information processing device is used to estimate a communication bandwidth.
[0125] For example, the estimation unit 111 computes the difference between the (K+1)-th timing associated with a first state and the K-th timing associated with the first state on the base of the history information 405 . For convenience of explanation, the difference is referred to as a “first transmission interval”. In other words, the first transmission interval represents the length of the period while the communication unit 407 is estimated to be in the first state between the K-th timing and the (K+1)-th timing. Similarly, the estimation unit 111 computes the difference between the (K+1)-th timing associated with the second state and the K-th timing associated with the first state on the base of the history information 405 . For the convenience of explanation, the difference is referred to as a “second transmission interval”. In other words, the second transmission interval represents the length of the period from the K-th timing to the (K+1)-th timing and the period while the communication unit 407 changes from the first state to the second state. For example, the estimation unit 111 estimates the first period by computing the average of the maximum value among first transmission intervals and the minimum value among second transmission intervals.
[0126] The procedure with which the estimation unit 111 estimates the first period is not limited to the method described above; for example, the procedure may estimate the average over the averaged first transmission intervals and the averaged second transmission intervals as the first period. The procedure may estimate the average over the minimum value of first transmission intervals and the maximum value of second transmission intervals as the first period. The procedure may estimate the maximum value of second transmission intervals as the first period.
[0127] Then, the determination unit 109 determines whether or not the first period is shorter than the second period (step S 105 ). Here, the first period is an estimated time between the end of processing and the timing at which the communication unit 407 is set to the second state after executing some processing.
[0128] When the determination unit 109 determines that the estimated first period is shorter than the second period (YES at step S 105 ), the determination unit 109 transmits a setting signal to the second information processing device 402 in the second period (step S 110 ). When the determination unit 109 determines that the estimated first period is longer than or equal to the second period (NO at step S 105 ), the determination unit 109 does not perform the process illustrated in step S 110 .
[0129] In the history information 405 , at least one of the type of hardware relating to the second information processing device 402 and the type of software relating to the second information processing device 402 may also be associated with information described above.
[0130] For example, in this case, the estimation unit 111 refers to at least one of the type of hardware relating to an information processing device used for estimation of a communication bandwidth (referred to as the “third information processing device” for convenience of explanation) and the type of software relating to the third information processing device. For example, the estimation unit 111 reads information associated with a type of hardware that is the same as (or similar to) the type of hardware relating to the third information processing device from the history information 405 and estimates the first period on the base of the read information in accordance with the procedure as described above.
[0131] For example, the estimation unit 111 reads information associated with a type of software that is the same as (or similar to) the type of software relating to the third information processing device from the history information 405 and estimates the first period on the base of the read information in accordance with the procedure as described above. Alternatively, the estimation unit 111 reads information associated with types that are the same as (or similar to) the above-mentioned two types relating to the third information processing device from the history information 405 and estimates the first period on the base of the read information in accordance with the procedure as described above.
[0132] Advantageous effects of the setting device 112 according to the third example embodiment will be described next.
[0133] The setting device 112 according to the present example embodiment enables precise estimation of a communication bandwidth. Further, the setting device 112 according to the present example embodiment enables a communication bandwidth to be precisely estimated even when the first period is unknown.
[0134] This is because of reasons 1 and 2:
[0135] (Reason 1) The configuration of the setting device 112 according to the third example embodiment includes a configuration similar to the setting device 101 according to the first example embodiment, and
[0136] (Reason 2) The estimation unit 111 estimates the first period on the base of the history information 405 even when the first period is unknown.
[0137] Further, if the history information 405 includes at least one of the type of hardware and the type of software, the setting device 112 according to the third example embodiment can provide an environment that enables a communication bandwidth to be more precisely estimated. This is because the second period often depends on at least one of the type of hardware and the type of software.
[0138] The estimation unit 111 estimates the first period on the base of the history information 405 associated with at least one of the type of hardware and the type of software. Since the first period often depends on at least one of the type of hardware and the type of software, the estimation unit 111 can estimate the first period more precisely. Consequently, the transmission unit 110 can transmit a setting signal at an appropriate timing and thus the setting device 112 according to this example embodiment can provide an environment that enables a communication bandwidth to be more precisely estimated.
[0139] (Hardware Configuration Example)
[0140] A configuration example of hardware resources that realize setting devices in the above-described example embodiments of the present invention using a single calculation processing apparatus (an information processing apparatus or a computer) will be described. However, the setting devices may be realized using physically or functionally at least two calculation processing apparatuses. Further, the setting devices may be realized as a dedicated apparatus.
[0141] FIG. 14 is a block diagram schematically illustrating a hardware configuration of a calculation processing apparatus capable of realizing the setting devices according to first to third example embodiments. A calculation processing apparatus 20 includes a central processing unit (CPU) 21 , a memory 22 , a disc 23 , and a non-transitory recording medium 24 . A calculation processing apparatus 20 further includes an input apparatus 25 , an output apparatus 26 , a communication interface (hereinafter, expressed as a “communication I/F”) 27 and a display 28 . The calculation processing apparatus 20 can execute transmission/reception of information to/from another calculation processing apparatus and a communication apparatus via the communication I/F 27 .
[0142] The non-volatile recording medium 24 is, for example, a computer-readable Compact Disc, Digital Versatile Disc. The non-volatile recording medium 24 may be Universal Serial Bus (USB) memory, Solid State Drive or the like. The non-transitory recording medium 24 allows a related program to be holdable and portable without power supply. The non-transitory recording medium 24 is not limited to the above-described media. Further, a related program can be carried via a communication network by way of the communication I/F 27 instead of the non-transitory medium 24 .
[0143] In other words, the CPU 21 copies, on the memory 22 , a software program (a computer program: hereinafter, referred to simply as a “program”) stored by the disc 23 when executing the program and executes arithmetic processing. The CPU 21 reads data necessary for program execution from the memory 22 . When display is needed, the CPU 21 displays an output result on the display 28 . When a program is input from the outside, the CPU 21 reads the program from the input apparatus 25 . The CPU 21 interprets and executes an setting program ( FIG. 2 , “setting device” in FIG. 3 , “server device” in FIG. 8 , FIG. 10 , “setting device” in FIG. 11 or FIG. 13 ) present on the memory 22 corresponding to a function (processing) indicated by each unit illustrated in FIG. 1 , FIG. 5 , FIG. 6 , FIG. 7 , FIG. 9 , or FIG. 12 described above. The CPU 21 sequentially executes the processing described in each example embodiment of the present invention.
[0144] In other words, in such a case, it is conceivable that the present invention can also be made using the setting program. Further, it is conceivable that the present invention can also be made using a computer-readable, non-transitory recording medium storing the setting program.
[0145] The present invention has been described using the above-described example embodiments as example cases.
[0146] However, the present invention is not limited to the above-described example embodiments. In other words, the present invention is applicable with various aspects that can be understood by those skilled in the art without departing from the scope of the present invention.
[0147] This application is based upon and claims the benefit of priority from Japanese patent application No. 2014-233883, filed on Nov. 18, 2014, the disclosure of which is incorporated herein in its entirety.
REFERENCE SIGNS LIST
[0000]
101 Setting device
102 Transmission unit
401 First information processing device
402 Second information processing device
403 Communication network
404 Bandwidth estimation device
406 Communication control unit
407 Communication unit
103 Control unit
104 Estimation unit
105 Communication system
113 Second information processing device
106 Client device
107 Server device
108 Setting device
109 Determination unit
110 Transmission unit
111 Estimation unit
112 Setting device
405 History information
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Provided is a setting device and the like with which correct estimation of a communication band is possible. The setting device 101 has a transmission unit 102 that, on the basis of a first timing at which a first information processing device 401 transmits to a second information processing device 402 a first signal for measuring a communication band which pertains to a communication network 403 , transmits to the second information processing device 402 a setting signal for setting a communication unit 407 of the second information processing device 402 to a communication-enabled state.
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FIELD OF INVENTION
[0001] The present invention relates to 2-indolinone derivatives which are capable of inhibiting protein kinases and histone deacetylases. The compounds of this invention are therefore useful in treating diseases associated with abnormal protein kinase activities or abnormal histone deacetylase activities. Pharmaceutical compositions comprising these compounds, methods of treating diseases utilizing pharmaceutical compositions comprising these compounds, and methods of preparing these compounds are also disclosed.
BACKGROUND OF THE INVENTION
[0002] The favorite metaphor for cancer drug developers has long been target therapy, wherein a drug is designed to hit tumor cells at one specific target, knocking them out while leaving normal cells undamaged. Cancer cells, however, can use multiple biological triggers and pathways to grow and spread throughout the body. Hitting cancer cells at one target will allow them to regroup and redeploy along new growth paths. This realization has led to the development of combination target therapies, which are becoming the new paradigm for cancer treatment.
[0003] Several multi-target kinase inhibitors are now in development, two, (Sorafenib and Suten) are already approved in the United States. Sorafenib, developed by Bayer Pharmaceuticals, is the first drug targeting both the RAF/MEK/ERK pathway (involved in cell proliferation) and the VEGFR2/PDGFRβ signaling cascade (involved in angiogenesis). Sorafenib was first approved in December 2005 for advanced kidney cancer, a disease that is believed to be highly dependent on angiogenesis. Although some of these target therapies have been found to be effective against solid tumors, they remain far from satisfactory in terms of achieving better efficacy and minimizing treatment side-effects. Thus, the search for target therapies continues. One option is develop agents that inhibit protein kinsases as well as histone deacetylases.
[0004] Protein kinases are a family of enzymes that catalyze the phosphorylation of proteins, in particular the hydroxy group of specific tyrosine, serine and threonine residues in proteins. Protein kinases play a critical role in the regulation of a wide variety of cellular processes, including metabolism, cell proliferation, cell differentiation, cell survival, environment-host reactions, immune responses, and angiogenesis. Many diseases are associated with abnormal cellular responses triggered by protein kinase—mediated events. These diseases include inflammatory diseases, autoimmune diseases, cancer, neurological and neurodegenerative diseases, cardiovascular diseases, allergies and asthma or hormone-related disease (Tan, S-L., 2006, J. Immunol., 176: 2872-2879; Healy, A. ea al., 2006, J. Immunol., 177: 1886-1893; Salek-Ardakani, S. et al., 2005, J. Immunol., 175: 7635-7641; Kim, J. et al., 2004, J. Clin. Invest., 114: 823-827). Therefore, considerable effort has been made to identify protein kinase inhibitors that are effective as therapeutic agents against these diseases.
[0005] The protein kinases can be conventionally divided into two classes, the protein tyrosine kinases (PTKs) and the serine-threonine kinases (STKs).
[0006] The protein tyrosine kinases (PTKs) are divided into two classes: the non-transmembrane tyrosine kinases and transmembrane growth factor receptor tyrosine kinases (RTKs). At present, at least nineteen distinct subfamilies of RTKs have been identified, such as the epidermal growth factor receptor (EGFR), the vascular endothelial growth factor receptor (VEGFR), the platelet derived growth factor receptor growth factor receptor (PDGFR), and the fibroblast growth factor receptor (FGFR).
[0007] The epidermal growth factor receptor (EGFR) family comprises four transmembrane tyrosine kinase growth factor receptors: HER1, HER2, HER3 and HER4. Binding of a specific set of ligands to the receptor promotes EGFR dimerization and results in the receptors autophosphorylation on tyrosine residues (Arteaga, C-L., 2001, Curr. Opin. Oncol., 6: 491-498). Upon autophosphorylation of the receptor several signal transduction pathways downstream of EGFR become activated. The EGFR signal transduction pathways have been implicated in the regulation of various neoplastic processes, including cell cycle progression, inhibition of apoptosis, tumor cell motility, invasion and metastasis. EGFR activation also stimulates vascular endothelial growth factor (VEGF), which is the primary inducer of angiogenesis (Petit, A-M. et al., 1997, Am. J. Pathol., 151: 1523-1530). In experimental models, deregulation of the EGFR-mediated signal transduction pathways is associated with oncogenesis (Wikstrand, C-J. et al., 1998, J Natl Cancer Inst., 90: 799-800). Mutations leading to continuous activation of amplification and over expression of EGFR proteins are seen in many human tumors, including tumors of breast, lung, ovaries and kidney. These mutations are a determinant of tumor aggressiveness (Wikstrand, C-J. et al., 1998, J Natl Cancer Inst., 90: 799-800). EGFR over expression is frequently seen in non-small cell lung cancer (NSCLC). Activity of EGFR can be inhibited either by blocking the extracellular ligand binding domain with the use of anti-EGFR antibodies or by the use of small molecules that inhibit the EGFR tyrosine kinase, thus resulting in inhibition of downstream components of the EGFR pathway (Mendelsohn, J., 1997, Clin. Can. Res., 3: 2707-2707).
[0008] The vascular endothelial growth factor (VEGF) is secreted by almost all solid tumors and tumor associated stroma in response to hypoxia. It is highly specific for vascular endothelium and regulates both vascular proliferation and permeability. Excessive expression of VEGF levels correlate with increased microvascular density, cancer recurrence and decreased survival (Parikh, A-A., 2004;, Hematol. Oncol. Clin. N. Am., 18:951-971). There are 6 different ligands for the VEGF receptor, VEGF-A through -E and placenta growth factor. Ligands bind to specific receptors on endothelial cells, mostly VEGFR-2. The binding of VEGF-A to VEGFR-1 induces endothelial cell migration. Binding to VEGFR-2 induces endothelial cell proliferation, permeability and survival. VEGFR-3 is thought to mediate lymphangiogenesis. The binding of VEGF to VEGFR-2 receptors results in activation and autophosphorylation of intracellular tyrosine kinase domains which further triggers other intracellular signaling cascades (Parikh, A-A., 2004, Hematol. Oncol. Clin. N. Am., 18:951-971).
[0009] The serine-threonine kinases (STKs) are predominantly intracellular although there are a few receptor kinases of the STK type. STKs are the most common forms of the cytosolic kinases that perform their function in the part of the cytoplasm other than the cytoplasmic organelles and cytoskelton.
[0010] Glycogen synthase kinase-3 (GSK-3) is a serine-threonine protein kinase comprised of α and β isoforms that are each encoded by distinct genes. GSK-3 has been found to phosphorylate and modulate the activity of a number of regulatory proteins. GSK-3 has been implicated in various diseases including diabetes, Alzheimer's disease, CNS disorders such as manic depressive disorder and neurodegenerative diseases, and cardiomyocyte hypertrophy (Haq, et al., 2000, J. Cell Biol., 151: 117).
[0011] Aurora-2 is a serine-threonine protein kinase that has been implicated in human cancer, such as colon, breast, and other solid tumors. This kinase is believed to be involved in protein phosphorylation events that regulate cell cycle. Specifically, Aurora-2 may play a role in controlling the accurate segregation of chromosomes during mitosis. Misregulation of the cell cycle can lead to cellular proliferation and other abnormalities. In human colon cancer tissue, the Aurora-2 protein has been found to be over expressed (Schumacher, et al., 1998, J. Cell Biol., 143: 1635-1646; Kimura et al., 1997, J. Biol. Chem., 272: 13766-13771).
[0012] The cyclin-dependent kinases (CDKs) are serine-threonine protein kinase that regulate mammalian cell division. CDKs play a key role in regulating cell machinery. To date, nine kinase subunits (CDK 1-9) have been identified. Each kinase associates with a specific regulatory partner which together make up the active catalytic moiety. Uncontrolled proliferation is a hallmark of cancer cells, and misregulation of CDK function occurs with high frequency in many important solid tumors. CDK2 and CDK4 are of particular interest because their activities are frequently misregulated in a wide variety of human cancers.
[0013] Raf kinase, a downstream effector of ras oncoprotein, is a key mediator of signal-transduction pathways from cell surface to the cell nucleus. Inhibition of raf kinase has been correlated in vitro and in vivo with inhibition of the growth of variety of human tumor types (Monia et al., 1996, Nat. Med., 2: 668-675).
[0014] Other serine-threonine protein kinases include the protein kinase A, B and C. These kinases, known as PKA, PKB and PKC, play key roles in signal transduction pathways.
[0015] Many attempts have been made to identify small molecules which act as protein kinase inhibitors useful in the treatment of diseases associated with abnormal protein kinase activities. For example, cyclic compounds (U.S. Pat. No. 7,151,096), bicyclic compounds (U.S. Pat. No. 7,189,721), tricyclic compounds (U.S. Pat. No. 7,132,533), (2-oxindol-3-ylidenyl) acetic acid derivatives (U.S. Pat. No. 7,214,700), 3-(4-amidopyrrol-2-ylmethlidene)-2-indolinone derivatives (U.S. Pat. No. 7,179,910), fused pyrazole derivatives (U.S. Pat. No. 7,166,597), aminofurazan compounds (U.S. Pat. No. 7,157,476), pyrrole substituted 2-indolinone compounds (U.S. Pat. No. 7,125,905), triazole compounds (U.S. Pat. No. 7,115,739), pyrazolylamine substituted quinazoline compounds (U.S. Pat. No. 7,098,330) and indazole compounds (U.S. Pat. No. 7,041,687) have all been described as protein kinase inhibitors. Several protein kinase inhibitors such as Glivec, Suten, and Sorafenib have been successfully approved by the FDA as anti-cancer therapies. Their clinical use demonstrated clear advantages over existing chemotherapeutical treatments, fueling continuing interest in the innovation of mechanism-based treatments using new compounds with chemical scaffold improvements with excellent oral bioavailability, significant anti-tumor activity, and lower toxicity at well-tolerated dose.
[0016] Histone deacetylase (HDAC) proteins play a critical role in regulating gene expression in vivo by altering the accessibility of genomic DNA to transcription factors. Specifically, HDAC proteins remove the acetyl group of acetyl-lysine residues on histones, which can result in nucleosomal remodelling (Grunstein, M., 1997, Nature, 389: 349-352). Due to their governing role in gene expression, HDAC proteins are associated with a variety of cellular events, including cell cycle regulation, cell proliferation, differentiation, reprogramming of gene expression, and cancer development (Ruijter, A-J-M., 2003, Biochem. J., 370: 737-749; Grignani, F., 1998, Nature, 391: 815-818; Lin, R-J., 1998, 391: 811-814; Marks, P-A., 2001, Nature Reviews Cancer, 1: 194). In fact, HDAC inhibitors have been demonstrated to reduce tumor growth in various human tissues and in animal studies, including lung, stomach, breast, and prostrate (Dokmanovic, M., 2005, J. Cell Biochenm., 96: 293-304).
[0017] Mammalian HDACs can be divided into three classes according to sequence homology. Class I consists of the yeast Rpd3-like proteins (HDAC 1, 2, 3, 8 and 11). Class II consists of the yeast HDA1-like proteins (HDAC 4, 5, 6, 7, 9 and 10). Class III consists of the yeast SIR2-like proteins (SIRT 1, 2, 3, 4, 5, 6 and 7).
[0018] The activity of HDAC1 has been linked to cell proliferation, a hallmark of cancer. Particularly, mammalian cells with knock down of HDAC1 expression using siRNA were antiproliferative (Glaser, K-B., 2003, Biochem. Biophys. Res. Comm., 310: 529-536). While the knock out mouse of HDAC1 was embryonic lethal, the resulting stem cells displayed altered cell growth (Lagger, G., 2002, EMBO J., 21: 2672-2681). Mouse cells overexpressing HDAC1 demonstrated a lengthening of G 2 and M phases and reduced growth rate (Bartl. S., 1997, Mol. Cell Biol., 17: 5033-5043). Therefore, the reported data implicate HDAC1 in cell cycle regulation and cell proliferation.
[0019] HDAC2 regulates expression of many fetal cardiac isoforms. HDAC2 deficiency or chemical inhibition of histone deacetylase prevented the re-expression of fetal genes and attenuated cardiac hypertrophy in hearts exposed to hypertrophic stimuli. Resistance to hypertrophy was associated with increased expression of the gene encoding inositol polyphosphate-5-phosphatase f (Inpp5f) resulting in constitutive activation of glycogen synthase kinase 3β (Gsk3β) via inactivation of thymoma viral proto-oncogene (Akt) and 3-phosphoinositide-dependent protein kinase-1 (Pdk1). In contrast, HDAC2 transgenic mice had augmented hypertrophy associated with inactivated Gsk3β. Chemical inhibition of activated Gsk3β allowed HDAC2-deficient adults to become sensitive to hypertrophic stimulation. These results suggest that HDAC2 is an important molecular target of HDAC inhibitors in the heart and that HDAC2 and Gsk3β are components of a regulatory pathway providing an attractive therapeutic target for the treatment of cardiac hypertrophy and heart failure (Trivedi, C-M., 2007, Nat. Med. 13: 324-331).
[0020] HDAC3 are maximally expressed in proliferating crypt cells in normal intestine. Silencing of HDAC3 expression in colon cancer cell lines resulted in growth inhibition, a decrease in cell survival, and increased apoptosis. Similar effects were observed for HDAC2 and, to a lesser extent, for HDAC1. HDAC3 gene silencing also selectively induced expression of alkaline phosphatase, a marker of colon cell maturation. Concurrent with its effect on cell growth, overexpression of HDAC3 inhibited basal and butyrate-induced p21 transcription in a Sp1/Sp3-dependent manner, whereas silencing of HDAC3 stimulated p21 promoter activity and expression. These findings identify HDAC3 as a gene deregulated in human colon cancer and as a novel regulator of colon cell maturation and p21 expression (Wilson, A-J., 2006, J. Biol. Chem., 281: 13548-13558).
[0021] HDAC6 is a subtype of the HDAC family that deacetylates alpha-tubulin and increases cell motility. Using quantitative real-time reverse transcription polymerase chain reaction and Western blots on nine oral squamous cell carcinoma (OSCC)-derived cell lines and normal oral keratinocytes (NOKs), HDAC6 mRNA and protein expression were commonly up-regulated in all cell lines compared with the NOKs. Immunofluorescence analysis detected HDAC6 protein in the cytoplasm of OSCC cell lines. Similar to OSCC cell lines, high frequencies of HDAC6 up-regulation were evident in both mRNA (74%) and protein (51%) levels of primary human OSCC tumors. Among the clinical variables analyzed, the clinical tumor stage was found to be associated with the HDAC6 expression states. The analysis indicated a significant difference in the HDAC6 expression level between the early stage (stage I and II) and advanced-stage (stage III and IV) tumors (P=0.014). These results suggest that HDAC6 expression may be correlated with tumor aggressiveness and offer clues to the planning of new treatments (Sakuma, T., 2006, Int. J. Oncol., 29: 117-124).
[0022] Epigenetic silencing of functional chromosomes by HDAC is one of the major mechanisms that occurrs in pathological processes in which functionally critical genes are repressed or reprogrammed by HDAC activities leading to the loss of phenotypes in terminal differentiation, maturation and growth control, and the loss of functionality of tissues. For example, tumor suppressor genes are often silenced during development of cancer and chemical inhibitors of HDAC can derepress the expression of these tumor suppressor genes, leading to growth arrest and differentiation (Glaros S et al., 2007, Oncogene June 4 Epub ahead of print; Mai, A, et al., 2007, Int J. Biochem Cell Bio., April 4, Epub ahead of print; Vincent A. et al., 2007, Oncogene, April 30, Epub ahead of print; our unpublished results). Repression of structural genes such as FXN in Friedreich's ataxia and SMN in spinal muscular atrophy can be reversed by HDAC inhibitors, leading to re-expression and resumption of FXN and SMN gene function in tissues (Herman D et al., 2006, Nature Chemical Biology, 2(10):551-8; Avila AM et al., 2007, J Clinic Investigation, 117(3)659-71; de Bore J, 2006, Tissue Eng. 12(10):2927-37); Induction of the entire MHC II family gene expression through reprogramming of HDAC “hot spot” in chromosome 6p21-22 by HDAC inhibitors further extends epigenetic modulation of immune recognition and immune response (Gialitakis M et al., 2007, Nucleic Acids Res., 34(1);765-72).
[0023] Several classes of HDAC inhibitors have been identified, including (1) short-chain fatty acids, e.g. butyrate and phenylbutyrate; (2) organic hydroxamic acids, e.g. suberoylanilide hydroxamic acid (SAHA) and trichostatin A (TSA); (3) cyclic tetrapeptides containing a 2-amino-8-oxo 9,10-expoxydecanoyl (AOE) moiety, e.g. trapoxin and HC-toxin; (4) cyclic peptides without the AOE moiety, e.g. apicidin and FK228; and (5) benzamides, e.g. MS-275 (EP0847992A1, US2002/0103192A1, W002/26696A1, WO01/70675A2, WO01/18171A2). HDAC represents a very promising drug target especially in the context of epigenic biology; for example, in terms of preferential apoptosis-induction in malignant cells but not normal cells, differentiation of epithelia in cancer cells, anti-inflammatory and immunomodulation, and cell cycle arrest.
[0024] The use of HDAC inhibitors can be considered as “neo-chemotherapy” having a much improved toxicity profile over existing chemotherapy options. The success of SAHA from Merck is currently only limited to the treatment of cutaneous T cell lymphoma. No reports exist indicating that SAHA treatment is effective against major solid tumors or for any other indications. Therefore, there is still a need to discover new compounds with improved profiles, such as stronger HDAC inhibitory activity and anti-cancer activity, more selective inhibition on different HDAC subtypes, and lower toxicity; There is a continuing need to identify novel HDAC inhibitors that can be used to treat potential new indications such as neurological and neurodegenerative disorders, cardiovascular disease, metabolic disease, and inflammatory and immunological diseases.
SUMMARY OF THE INVENTION
[0025] The present invention is directed to certain 2-indolinone derivatives which are capable of selectively inhibiting protein kinases and histone deacetylases and are therefore useful in treating diseases associated with abnormal protein kinase activities and abnormal histone deacetylase activities. In particular, the compounds are highly effective against hematological malignancy and solid carcinomas.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Various publications are cited throughout the present application. The contents of these publications and contents of documents cited in these publications are incorporated herein by reference.
[0027] Provided herein are new chemical compounds that combine anti-angiogenesis and anti-proliferation activities of RTK's together with differentiation-inducing, immune modulation, cell cycle arrest and apoptosis-induction activities of more selective HDACi, to reach a better efficacy against solid tumors while overcoming side effects such as hypertension, QT prolongation, thyroid gland regression, skin rash and discoloration, and pains associated with currently marketed RTK inhibitors.
[0028] Particularly, the present invention provides a compound having the structure represented by formula (I), or its stereoisomer, enantiomer, diastereomer, hydrate, or pharmaceutically acceptable salts thereof:
[0000]
[0029] wherein
X is ═CH— or ═N—N═CH—; R 1 , R 2 , R 3 and R 4 are independently hydrogen, halo, alkyl alkoxy, nitro or trifluoromethyl; R 5 , R 6 , R 7 and R 8 are independently hydrogen, halo, alkyl alkoxy or trifluoromethyl; n is an integer ranging from 2 to 6.
[0033] In the above structural formula (I) and throughout the present specification, the following terms have the indicated meaning:
[0034] The term “halo” as used herein means fluorine, chlorine, bromine or iodine.
[0035] The term “alkyl” as used herein includes methyl, ethyl, n-propyl, iso-propyl, butyl, iso-butyl, sec-butyl, tert-butyl and the like.
[0036] The term “alkoxy” as used herein includes methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy and the like.
[0037] In one embodiment of a compound of formula (I), X is ═CH—; R 1 , R 2 , R 3 and R 4 are independently hydrogen, halo, alkyl alkoxy, nitro or trifluoromethyl; R 5 , R 6 , R 7 and R 8 are independently hydrogen, halo, alkyl alkoxy or trifluoromethyl; and n is an integer ranging from 2 to 4.
[0038] In another embodiment, X is ═CH—; R 1 , R 2 , R 3 and R 4 are independently hydrogen, halo, alkyl alkoxy, nitro or trifluoromethyl; R 5 , R 6 , R 7 and R 8 are independently H or F;and n is an integer ranging from 2 to 4.
[0039] In another embodiment, X is ═N—N═CH—; R 1 , R 2 , R 3 and R 4 are independently hydrogen, halo, alkyl alkoxy, nitro or trifluoromethyl; R 5 , R 6 , R 7 and R 8 are independently hydrogen, halo, alkyl alkoxy or trifluoromethyl; and n is an integer ranging from 2 to 4.
[0040] In another embodiment, X is ═N—N═CH—; R 1 , R 2 R 3 and R 4 are independently hydrogen, halo, alkyl alkoxy, nitro or trifluoromethyl; R 5 , R 6 , R 7 and R 8 are independently H or F; and n is an integer ranging from 2 to 4.
[0041] The compounds of this invention are prepared as described below:
[0042] (a) 6-Chloronicotinic acid is condensed with compound 1 to give compound 2;
[0000]
[0043] (b) Compound 2 is condensed with compound 3 to give compound 4;
[0000]
[0044] (c) Compound 4 is condensed with compound 5 to give compound 6.
[0000]
[0045] Condensation reactions (a) and (c) are conducted by using a peptide condensing agent such as 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide (EDC), dicyclohexylcarbodiimide (DCC), N,N′-carbonyldiimidazole (CDI), etc. The reaction may be conducted at 0 to 80° C. for 4 to 72 hours. Solvents which may be used are normal solvents such as benzene, toluene, tetrahydrofuran, dioxane, dichloromethane, chloroform, N,N-dimethylformamide, etc. If necessary, a base such as sodium hydroxide, triethylamine and pyridine may be added to the reaction system.
[0046] Condensation reaction (b) is conducted at 40 to 120° C. for 1 to 24 hours. Solvents which may be used are normal solvents such as benzene, toluene, tetrahydrofuran, dioxane, dichloromethane, chloroform, N,N-dimethylformamide, etc. If necessary, a base such as sodium hydroxide, triethylamine and pyridine may be added to the reaction system.
[0047] The compounds represented by formula (I) and the intermediate (2) and (4) may be purified or isolated by the conventional separation methods such as extraction, recrystallization, column chromatography and the like.
[0048] The compounds represented by formula (I) are capable of inhibiting protein kinases and histone deacetylases and are therefore useful in treating diseases associated with abnormal protein kinase activities and abnormal histone deacetylase activities. In particular, they are highly effective against hematological malignancy and solid carcinomas.
[0049] The compounds represented by formula (I) useful as a drug may be used in the form of a general pharmaceutical composition. The pharmaceutical composition may be in the forms normally employed, such as tablets, capsules, powders, syrups, solutions, suspensions, aerosols, and the like, may contain flavorants, sweeteners etc. in suitable solids or liquid carriers or diluents, or in suitable sterile media to form injectable solutions or suspensions. Such composition typically contains from 0.5 to 70%, preferably 1 to 20% by weight of active compound, the remainder of the composition being pharmaceutically acceptable carriers, diluents or solvents or salt solutions.
[0050] The compounds represented by formula (I) are clinically administered to mammals, including man and animals, via oral, nasal, transdermal, pulmonary, or parenteral routes. Administration by the oral route is preferred, being more convenient and avoiding the possible pain and irritation of injection. By either route, the dosage is in the range of about 0.0001 to 200 mg/kg body weight per day administered singly or as a divided dose. However, the optimal dosage for the individual subject being treated will be determined by the person responsible for treatment, generally smaller dose being administered initially and thereafter increments made to determine the most suitable dosage.
[0051] Representative compounds of the present invention are shown in Table 1 below. The compound numbers correspond to the “Example numbers” in the Examples section. That is, the synthesis of compound 3 as shown in the Table 1 is described in “Example 3” and the synthesis of compound 51 as shown in the Table 1 is described in “Example 51”. The compounds presented in the Table 1 are exemplary only and are not to be construed as limiting the scope of this invention in any manner.
[0000]
TABLE 1
Example
Structure
Name
3
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((5-fluoro-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethylamino)-nicotinamide
4
N-(2-Aminophenyl)-6-(2-(2-(((5- fluoro-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethylamino)nicotinamide
6
(Z)-N-(2-Aminophenyl)-6-(3-(2- ((5-fluoro-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- propylamino)-nicotinamide
7
N-(2-Aminophenyl)-6-(3-(2-(((5- fluoro-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- propylamino)nicotinamide
9
(Z)-N-(2-Aminophenyl)-6-(4-(2- ((5-fluoro-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)-butylamino)-nicotinamide
10
N-(2-Aminophenyl)-6-(4-(2-(((5- fluoro-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- butylamino)nicotinamide
13
(Z)-N-(2-Amino-4-fluorophenyl)- 6-(2-(2-((5-fluoro-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethylamino)nicotinamide
14
N-(2-Amino-4-fluorophenyl)-6-(2- (2-(((5-fluoro-2-oxoindolin-3- ylidene)hydrazono)methyl)-3,5- dimethyl-1H-pyrrole-4- carboxamido)ethylamino)- nicotinamide
16
(Z)-N-(2-Amino-4-fluorophenyl)- 6-(3-(2-((5-fluoro-2-oxoindolin- 3-ylidene)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- propyl-amino)nicotinamide
17
N-(2-Amino-4-fluorophenyl)-6-(3- (2-(((5-fluoro-2-oxoindolin-3- ylidene)hydrazono)methyl)-3,5- dimethyl-1H-pyrrole-4- carboxamido)propylamino)- nicotinamide
19
(Z)-N-(2-Amino-4-fluorophenyl)- 6-(4-(2-((5-fluoro-2-oxoindolin-3- ylidene)methyl)-3,5-dimethyl-1H- pyrrole-4-carboxamido)butyl- amino)nicotinamide
20
N-(2-Amino-4-fluorophenyl)-6-(4- (2-(((5-fluoro-2-oxoindolin-3- ylidene)hydrazono)methyl)-3,5- dimethyl-1H-pyrrole-4- carboxamido)butylamino)- nicotinamide
23
(Z)-N-(2-Amino-4-chlorophenyl)- 6-(2-(2-((5-fluoro-2-oxoindolin-3- ylidene)methyl)-3,5-dimethyl-1H- pyrrole-4-carboxamido)ethyl- amino)nicotinamide
24
N-(2-Amino-4-chlorophenyl)-6- (2-(2-(((5-fluoro-2-oxoindolin- 3-ylidene)hydrazono)methyl)- 3,5-dimethyl-1H-pyrrole-4- carboxamido)ethylamino)- nicotinamide
27
(Z)-N-(2-Amino-4-methylphenyl)- 6-(2-(2-((5-fluoro-2-oxoindolin-3- ylidene)methyl)-3,5-dimethyl-1H- pyrrole-4-carboxamido)ethyl- amino)nicotinamide
28
N-(2-Amino-4-methylphenyl)-6- (2-(2-(((5-fluoro-2-oxoindolin-3- ylidene)hydrazono)methyl)-3,5- dimethyl-1H-pyrrole-4- carboxamido)ethylamino)- nicotinamide
31
(Z)-N-(2-Amino- 4-methoxyphenyl)-6-(2- (2-((5-fluoro-2-oxoindolin-3- ylidene)methyl)-3,5-dimethyl-1H- pyrrole-4-carboxamido)ethyl- amino)nicotinamide
32
N-(2-Amino-4-methylphenyl)-6- (2-(2-(((5-fluoro-2-oxoindolin-3- ylidene)hydrazono)methyl)-3,5- dimethyl-1H-pyrrole-4- carboxamido)ethylamino)- nicotinamide
35
(Z)-N- (2-Amino-4-trifluoromethyl- phenyl)-6-(2-(2-((5-fluoro- 2-oxoindolin-3- ylidene)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethylamino)-nicotinamide
36
N-(2-Amino-4-trifluoromethyl-phenyl)-6-(2-(2-(((5-fluoro-2- oxoindolin-3-ylidene)hydrazono)- methyl)-3,5-dimethyl-1H-pyrrole- 4-carboxamido)ethylamino)- nicotinamide
37
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((2-oxoindolin-3-ylidene)methyl)- 3,5-dimethyl-1H-pyrrole-4- carboxamido)ethylamino)- nicotinamide
38
N-(2-Aminophenyl)-6-(2-(2-(((2- oxoindolin-3-ylidene)hydrazono)- methyl)-3,5-dimethyl-1H-pyrrole- 4-carboxamido)ethylamino)- nicotinamide
39
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((5-chloro-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethylamino)-nicotinamide
40
N-(2-Aminophenyl)-6-(2-(2-(((5- chloro-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)ethyl- amino)nicotinamide
41
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((4-methyl-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethylamino)-nicotinamide
42
N-(2-Aminophenyl)-6-(2-(2-(((4- methyl-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)ethyl- amino)nicotinamide
43
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((5-nitro-2-oxoindolin-3-ylidene)- methyl)-3,5-dimethyl-1H-pyrrole- 4-carboxamido)ethylamino)- nicotinamide
44
N-(2-Aminophenyl)-6-(2-(2-(((5- nitro-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)ethyl- amino)nicotinamide
45
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((6-methoxy-2-oxoindolin-3- ylidene)methyl)-3,5-dimethyl-1H- pyrrole-4-carboxamido)ethyl- amino)nicotinamide
46
N-(2-Aminophenyl)-6-(2-(2-(((6- methoxy-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)ethyl- amino)nicotinamide
47
(Z)-N-(2-Aminophenyl)-6-(2-(2- ((6-trifluoromethyl-2-oxoindolin- 3-ylidene)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- ethyl-amino)nicotinamide
48
N-(2-Aminophenyl)-6-(2-(2-(((6- trifluoromethyl-2-oxoindolin-3- ylidene)hydrazono)methyl)-3,5- dimethyl-1H-pyrrole-4- carboxamido)ethylamino)- nicotinamide
50
(Z)-N-(2-Aminophenyl)-6-(6-(2- ((5-fluoro-2-oxoindolin-3- ylidene)-methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)- hexylamino)-nicotinamide
51
N-(2-Aminophenyl)-6-(6-(2-(((5- fluoro-2-oxoindolin-3-ylidene)- hydrazono)methyl)-3,5-dimethyl- 1H-pyrrole-4-carboxamido)hexyl- amino)nicotinamid
[0052] Further, all parts and percentages in the examples, as well as in the remainder of the specification, are by weight unless otherwise specified. Any range of numbers recited in the specification or paragraphs hereinafter describing or claiming various aspects of the invention, such as that representing a particular set of properties, units of measure, conditions, physical states or percentages, is intended to literally incorporate expressly herein by reference or otherwise, any number falling within such range, including any subset of numbers or ranges subsumed within any range so recited. The term “about” when used as a modifier for, or in conjunction with, a variable, is intended to convey that the numbers and ranges disclosed herein are flexible and that practice of the present invention by those skilled in the art using temperatures, concentrations, amounts, contents, carbon numbers, and properties that are outside of the range or different from a single value, will achieve the desired result.
EXAMPLE 1
Preparation of N-(2-aminophenyl)-6-chloronicotinamide
[0053]
[0054] 6-Chloronicotinic acid (157.5 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and o-phenylenediamine (216 mg, 2 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine and extracted with 200 ml of ethyl acetate. The ethyl acetate was removed under vacuum. To the residue was added 5 ml of absolute ethanol. The solids were collected by vacuum filtration, washed with absolute ethanol and dried under vacuum to give the title compound (138 mg, 56% yield) as a brown solid. LC-MS (m/z) 248 (M+1).
EXAMPLE 2
Preparation of N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide
[0055]
[0056] N-(2-Aminophenyl)-6-chloronicotinamide (248 mg, 1 mmol) and 5 ml of ethylenediamine were heated to 80° C. for 3 hours. The excess ethylenediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (150 mg, 55% yield) as a brown solid. LC-MS (m/z) 272 (M+1).
EXAMPLE 3
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((5-fluoro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0057]
[0058] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (493 mg, 89%) as a yellow solid. 1 H NMR (DMSO-d 6 )δ2.41 (s, 3H, pyrrole-CH 3 ), 2.43 (s, 3H, pyrrole-CH 3 ), 3.43 (m, 2H, CH 2 ), 3.48 (m, 2H, CH 2 ), 4.86 (s, 2H, benzene-NH 2 ), 6.56 (m, 2H), 6.76 (d, J=8.0 Hz, 1H), 6.84 (m, 1H), 6.92 (m, 2H), 7.12 (d, J=8.0 Hz, 1H), 7.26 (s 1H), 7.71˜7.77 (m, 3H), 7.94 (d,J=8.0 Hz, 1H), 8.65 (s, 1H), 9.38 (s, 1H, benzene-NH), 10.90 (s, 1H, indolinone-NH), 13.69 (s, 1H, pyrrole-NH). LC-MS (m/z) 554 (M+1).
EXAMPLE 4
Preparation of N-(2-aminophenyl)-6-(2-(2-(((5-fluoro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0059]
[0060] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (425 mg, 73%) as a red solid. 1 H NMR (DMSO-d 6 )δ2.35 (s, 3H, pyrrole-CH 3 ), 2.44 (s, 3H, pyrrole-CH 3 ), 3.42 (m, 2H, CH 2 ), 3.48 (m, 2H, CH 2 ), 4.85 (s, 2H, benzene-NH 2 ), 6.56 (m, 2H), 6.76 (d, J=8.0 Hz, 1H), 6.85 (m, 1H), 6.92 (m, 1H), 7.12 (d, J=8.0 Hz, 1H), 7.20˜7.25 (m, 2H), 7.71 (s, 1H), 7.93 (d, J=8.0 Hz, 1H), 8.33 (d, J=8.0 Hz, 1H), 8.64 (s, 2H), 9.38 (s, 1H, benzene-NH), 10.73 (s, 1H, indolinone-NH), 11.84 (s, 1H, pyrrole-NH). LC-MS (m/z) 582 (M+1).
EXAMPLE 5
Preparation of N-(2-aminophenyl)-6-(3-aminopropylamino)nicotinamide
[0061]
[0062] N-(2-Aminophenyl)-6-chloronicotinamide (248 mg, 1 mmol) and 6 ml of 1,3-propanediamine were heated to 80° C. for 3 hours. The excess 1,3-propanediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (168 mg, 59% yield) as a brown solid. LC-MS (m/z) 286 (M+1).
EXAMPLE 6
Preparation of (Z)-N-(2-aminophenyl)-6-(3-(2-((5-fluoro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)propylamino)nicotinamide
[0063]
[0064] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(3-aminopropylamino)nicotinamide (299 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (465 mg, 82%) as a yellow solid. 1 H NMR (DMSO-d 6 )δ1.79 (m, 2H, CH2), 2.42 (s, 3H, pyrrole-CH 3 ), 2.44 (s, 3H, pyrrole-CH 3 ), 3.30 (m, 2H, CH2), 3.38 (m, 2H, CH2), 4.85 (s, 2H, benzene-NH 2 ), 6.51 (m, 1H), 6.58 (m, 1H), 6.75 (d, J=8.0 Hz, 1H), 6.83 (t, J=8.0 Hz, 1H), 6.92 (m, 2H), 7.12 (d, J=8.0 Hz, 1H), 7.19 (s, 1H), 7.71˜7.77 (m, 3H), 7.91 (d, J=8.0 Hz, 1H), 8.64 (s, 1H), 9.37(s, 1H, benzene-NH), 10.90 (s, 1H, indolinone-NH), 13.68 (s, 1H, pyrrole-NH). LC-MS (m/z) 568 (M+1).
EXAMPLE 7
Preparation of N-(2-aminophenyl)-6-(3-(2-(((5-fluoro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)propylamino)nicotinamide
[0065]
[0066] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(3-aminopropylamino)nicotinamide (299 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (452 mg, 76%) as a red solid. 1 H NMR (DMSO-d 6 )δ1.78 (m, 2H, CH 2 ), 2.36 (s, 3H, pyrrole-CH 3 ), 2.45 (s, 3H, pyrrole-CH 3 ), 3.30 (m, 2H, CH 2 ), 3.38 (m, 2H, CH 2 ), 4.85 (s, 2H, benzene-NH 2 ), 6.51 (m, 1H), 6.57 (m, 1H), 6.75 (d, J=8.0 Hz, 1H), 6.85 (m, 1H), 6.93 (m, 1H), 7.12 (d, J=8.0 Hz, 1H), 7.20 (m, 2H), 7.71 (s, 1H), 7.92 (d, J=8.0 Hz, 1H), 8.34 (d, J=8.0 Hz, 1H), 8.64 (s, 2H), 9.37 (s, 1H, benzene-NH), 10.74 (s, 1H, indolinone-NH), 11.85 (s, 1H, pyrrole-NH). LC-MS (m/z) 596 (M+1).
EXAMPLE 8
Preparation of N-(2-aminophenyl)-6-(4-aminobutylamino)nicotinamide
[0067]
[0068] N-(2-Aminophenyl)-6-chloronicotinamide (248 mg, 1 mmol) and 7 ml of 1,4-butanediamine were heated to 80° C. for 3 hours. The excess 1,4-butanediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (158 mg, 53% yield) as a brown solid. LC-MS (m/z) 300 (M+1).
EXAMPLE 9
Preparation of (Z)-N-(2-aminophenyl)-6-(4-(2-((5-fluoro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)butylamino)nicotinamide
[0069]
[0070] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(4-aminobutylamino)nicotinamide (314 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (447 mg, 77%) as a yellow solid. 1 H NMR (DMSO-d 6 )δ1.59 (m, 4H, CH 2 CH 2 ), 2.39 (s, 3H, pyrrole-CH 3 ), 2.41 (s, 3H, pyrrole-CH 3 ), 3.25 (m, 4H, 2×CH 2 ), 4.85 (s, 2H, benzene-NH 2 ), 6.49 (m, 1H), 6.57 (m, 1H), 6.75 (d, J=8.0 Hz, 1H), 6.83 (m, 1H), 6.91 (m, 2H), 7.12 (d, J=8.0 Hz, 1H), 7.18 (s, 1H), 7.67˜7.76 (m, 3H), 7.90 (d, J=8.0 Hz, 1H), 8.63 (s, 1H), 9.35 (s, 1H, benzene-NH), 10.88 (s, 1H, indolinone-NH), 13.66 (s, 1H, pyrrole-NH). LC-MS (m/z) 582 (M+1).
EXAMPLE 10
Preparation of N-(2-aminophenyl)-6-(4-(2-(((5-fluoro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)butylamino)nicotinamide
[0071]
[0072] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(4-aminobutylamino)nicotinamide (314 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (444 mg, 73%) as a red solid. 1 H NMR (DMSO-d 6 )δ1.59 (m, 4H, CH 2 CH 2 ), 2.32 (s, 3H, pyrrole-CH 3 ), 2.43 (s, 3H, pyrrole-CH 3 ), 3.24 (m, 4H, 2×CH 2 ), 4.85 (s, 2H, benzene-NH 2 ), 6.49 (m, 1H), 6.57 (m, 1H), 6.76 (d, J=8.0 Hz, 1H), 6.85 (m, 1H), 6.93 (m, 1H), 7.12 (d, J=8.0 Hz, 1H), 7.20 (m, 2H), 7.67 (s, 1H), 7.89 (d, J=8.0 Hz, 1H), 8.33 (d, J=8.0 Hz, 1H), 8.63 (s, 2H), 9.35 (s, 1H, benzene-NH), 10.70 (s, 1H, indolinone-NH), 11.82 (s, 1H, pyrrole-NH). LC-MS (m/z) 610 (M+1).
EXAMPLE 11
Preparation of N-(2-amino-4-fluorophenyl)-6-chloronicotinamide
[0073]
[0074] 6-Chloronicotinic acid (157.5 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and 4-fluoro-o-phenylenediamine (151 mg, 1.2 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine and extracted with 200 ml of ethyl acetate. The ethyl acetate was removed under vacuum. To the residue was added 5 ml of absolute ethanol. The solids were collected by vacuum filtration, washed with absolute ethanol and dried under vacuum to give the title compound (193 mg, 73% yield) as a brown solid. LC-MS (m/z) 266 (M+1).
EXAMPLE 12
Preparation of N-(2-amino-4-fluorophenyl)-6-(2-aminoethylamino)nicotinamide
[0075]
[0076] N-(2-Amino-4-fluorophenyl)-6-chloronicotinamide (266 mg, 1 mmol) and 5 ml of ethylenediamine were heated to 80° C. for 3 hours. The excess ethylenediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (176 mg, 61 % yield) as a brown solid. LC-MS (m/z) 290 (M+1).
EXAMPLE 13
Preparation of (Z)-N-(2-amino-4-fluorophenyl)-6-(2-(2-((5-fluoro-2-oxoindolin-3-ylidene)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0077]
[0078] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-fluorophenyl)-6-(2-aminoethylamino)nicotinamide (303 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (457 mg, 80%) as a yellow solid. 1 H NMR (DMSO-d 6 )δ2.41 (s, 3H, pyrrole-CH 3 ), 2.43 (s, 3H, pyrrole-CH 3 ), 3.43 (m, 2H, CH 2 ), 3.48 (m, 2H, CH 2 ), 5.18 (s, 2H, benzene-NH 2 ), 6.33 (m, 1H), 6.53 (m, 2H), 6.84 (m, 1H), 6.91 (m, 1H), 7.07 (m, 1H), 7.25 (s, 1H), 7.71 (m, 3H), 7.92 (d, J=8.0 Hz, 1H), 8.64 (s, 1H), 9.31 (s, 1H, benzene-NH), 10.89 (s, 1H, indolinone-NH), 13.68 (s, 1H, pyrrole-NH). LC-MS (m/z) 572 (M+1).
EXAMPLE 14
Preparation of N-(2-amino-4-fluorophenyl)-6-(2-(2-(((5-fluoro-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0079]
[0080] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-fluorophenyl)-6-(2-aminoethylamino)nicotinamide (303 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (407 mg, 68%) as a red solid. 1 H NMR (DMSO-d 6 )δ2.35 (s, 3H, pyrrole-CH 3 ), 2.44 (s, 3H, pyrrole-CH 3 ), 3.42 (m, 2H, CH 2 ), 3.47 (m, 2H, CH 2 ), 5.18 (s, 2H, benzene-NH 2 ), 6.33 (m, 1H), 6.53 (m, 2H), 6.85 (m, 1H), 7.06 (m, 1H), 7.21˜7.25 (m, 2H), 7.71 (s, 1H), 7.93 (d, J=8.0 Hz, 1H), 8.33 (d, J=8.0 Hz, 1H), 8.64 (s, 2H) 9.31 (s, 1H, benzene-NH), 10.73 (s, 1H, indolinone-NH), 11.84 (s, 1H, pyrrole-NH). LC-MS (m/z) 600 (M+1).
EXAMPLE 15
Preparation of N-(2-amino-4-fluorophenyl)-6-(3-aminopropylamino)nicotinamide
[0081]
[0082] N-(2-amino-4-fluorophenyl)-6-chloronicotinamide (266 mg, 1 mmol) and 6 ml of 1,3-propanediamine were heated to 80° C. for 3 hours. The excess 1,3-propanediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (158 mg, 52% yield) as a brown solid. LC-MS (m/z) 304 (M+1).
EXAMPLE 16
Preparation of (Z)-N-(2-amino-4-fluorophenyl)-6-(3-(2-((5-fluoro-2-oxoindolin-3-ylidene)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)propylamino)nicotinamide
[0083]
[0084] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-fluorophenyl)-6-(3-aminopropylamino)nicotinamide (318 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (456 mg, 78%) as a yellow solid. 1 H NMR (DMSO-d 6 )δ 1.78 (m, 2H, CH 2 ), 2.42 (s, 3H, pyrrole-CH 3 ), 2.44 (s, 3H, pyrrole-CH 3 ), 3.30 (m, 2H, CH 2 ), 3.38 (m, 2H, CH 2 ), 5.18 (s, 2H, benzene-NH 2 ), 6.33 (m, 1H), 6.51 (m, 2H), 6.84 (m, 1H), 6.90 (m, 1H), 7.06 (t, J=8.0 Hz, 1H), 7.20 (s, 1H), 7.71˜7.76 (m, 3H), 7.91 (d, J=8.0 Hz, 1H), 8.63 (s, 1H), 9.30 (s, 1H, benzene-NH), 10.90 (s, 1H, indolinone-NH), 13.68 (s, 1H, pyrrole-NH). LC-MS (m/z) 586 (M+1).
EXAMPLE 17
Preparation of N-(2-amino-4-fluorophenyl)-6-(3-(2-(((5-fluoro-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)propylamino)nicotinamide
[0085]
[0086] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-fluorophenyl)-6-(3-aminopropylamino)nicotinamide (318 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (441 mg, 72%) as a red solid. 1 H NMR (DMSO-d 6 )δ1.77 (m, 2H, CH 2 ), 2.36 (s, 3H, pyrrole-CH 3 ), 2.45 (s, 3H, pyrrole-CH 3 ), 3.29 (m, 2H, CH 2 ), 3.38 (m, 2H, CH 2 ), 5.18 (s, 2H, benzene-NH 2 ), 6.32 (m, 1H), 6.51 (m, 2H), 6.85 (m, 1H), 7.06 (m, 1H), 7.20 (m, 2H), 7.71 (s, 1H), 7.90 (d, J=8.0 Hz, 1H), 8.33 (d, J=8.0 Hz, 1H), 8.64 (s, 2H), 9.29 (s, 1H, benzene-NH), 10.73 (s, 1H, indolinone-NH), 11.84 (s, 1H, pyrrole-NH). LC-MS (m/z) 614 (M+1).
EXAMPLE 18
Preparation of N-(2-amino-4-fluorophenyl)-6-(4-aminobutylamino)nicotinamide
[0087]
[0088] N-(2-Amino-4-fluorophenyl)-6-chloronicotinamide (266 mg, 1 mmol) and 7 ml of 1,4-butanediamine were heated to 80° C. for 3 hours. The excess 1,4-butanediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (149 mg, 47% yield) as a brown solid. LC-MS (m/z) 318 (M+1).
EXAMPLE 19
Preparation of (Z)-N-(2-amino-4-fluorophenyl)-6-(4-(2-((5-fluoro-2-oxoindolin-3-ylidene)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)butylamino)nicotinamide
[0089]
[0090] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-fluorophenyl)-6-(4-aminobutylamino)nicotinamide (333 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (485 mg, 81%) as a yellow solid.
[0091] 1 H NMR (DMSO-d 6 )δ 1.59 (m, 4H, CH 2 CH 2 ), 2.39 (s, 3H, pyrrole-CH 3 ), 2.41 (s, 3H, pyrrole-CH 3 ), 3.24 (m, 2H, CH 2 ), 3.34 (m, 2H, CH 2 ), 5.17 (s, 2H, benzene-NH 2 ), 6.33 (m, 1H), 6.50 (m, 2H), 6.83 (m, 1H), 6.91 (m, 1H), 7.06 (t, J=8.0 Hz, 1H), 7.18 (s, 1H), 7.67˜7.76 (m, 3H), 7.89 (d, J=8.0 Hz, 1H), 8.63 (s, 1H), 9.28 (s, 1H, benzene-NH), 10.89 (s, 1H, indolinone-NH), 13.67 (s, 1H, pyrrole-NH). LC-MS (m/z) 600 (M+1).
EXAMPLE 20
Preparation of N-(2-amino-4-fluorophenyl)-6-(4-(2-(((5-fluoro-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)butylamino)nicotinamide
[0092]
[0093] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-fluorophenyl)-6-(4-aminobutylamino)nicotinamide (333 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (433 mg, 69%) as a red solid. 1 H NMR (DMSO-d 6 )δ1.58 (m, 4H, CH 2 CH 2 ), 2.32 (s, 3H, pyrrole-CH 3 ), 2.42 (s, 3H, pyrrole-CH 3 ), 3.24 (m, 2H, CH 2 ), 3.35 (m, 2H, CH 2 ), 5.18 (s, 2H, benzene-NH 2 ), 6.33 (m, 1H), 6.50 (m, 2H), 6.85 (m, 1H), 7.06 (m, 1H), 7.20 (m, 2H), 7.67 (s, 1H), 7.89 (d, J=8.0 Hz, 1H), 8.33 (d, J=8.0 Hz, 1H), 8.63 (s, 2H), 9.29 (s, 1H, benzene-NH), 10.74 (s, 1H, indolinone-NH), 11.83 (s, 1H, pyrrole-NH). LC-MS (m/z) 628 (M+1).
EXAMPLE 21
Preparation of N-(2-amino-4-chlorophenyl)-6-chloronicotinamide
[0094]
[0095] 6-Chloronicotinic acid (157.5 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and 4-chloro-o-phenylenediamine (171 mg, 1.2 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine and extracted with 200 ml of ethyl acetate. The ethyl acetate was removed under vacuum. To the residue was added 5 ml of absolute ethanol. The solids were collected by vacuum filtration, washed with absolute ethanol and dried under vacuum to give the title compound (135 mg, 48% yield) as a brown solid. LC-MS (m/z) 282 (M+1).
EXAMPLE 22
Preparation of N-(2-amino-4-chlorophenyl)-6-(2-aminoethylamino)nicotinamide
[0096]
[0097] N-(2-Amino-4-chlorophenyl)-6-chloronicotinamide (282 mg, 1 mmol) and 5 ml of ethylenediamine were heated to 80° C. for 3 hours. The excess ethylenediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (180 mg, 59% yield) as a brown solid. LC-MS (m/z) 306 (M+1).
EXAMPLE 23
Preparation of (Z)-N-(2-amino-4-chlorophenyl)-6-(2-(2-((5-fluoro-2-oxoindolin-3-ylidene)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0098]
[0099] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-chlorophenyl)-6-(2-aminoethylamino)nicotinamide (321 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (446 mg, 76%) as a yellow solid. LC-MS (m/z) 588 (M+1).
EXAMPLE 24
Preparation of N-(2-amino-4-chlorophenyl)-6-(2-(2-(((5-fluoro-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0100]
[0101] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-chlorophenyl)-6-(2-aminoethylamino)nicotinamide (321 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (406 mg, 66%) as a red solid. LC-MS (m/z) 616 (M+1).
EXAMPLE 25
Preparation of N-(2-amin-4-methylophenyl)-6-chloronicotinamide
[0102]
[0103] 6-Chloronicotinic acid (157.5 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and 4-methyl-o-phenylenediamine (146 mg, 1.2 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine and extracted with 200 ml of ethyl acetate. The ethyl acetate was removed under vacuum. To the residue was added 5 ml of absolute ethanol. The solids were collected by vacuum filtration, washed with absolute ethanol and dried under vacuum to give the title compound (164 mg, 63% yield) as a brown solid. LC-MS (m/z) 262 (M+1).
EXAMPLE 26
Preparation of N-(2-amino-4-methylphenyl)-6-(2-aminoethylamino)nicotinamide
[0104]
[0105] N-(2-Amino-4-methyl-phenyl)-6-chloronicotinamide (261 mg, 1 mmol) and 5 ml of ethylenediamine were heated to 80° C. for 3 hours. The excess ethylenediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (145 mg, 51% yield) as a brown solid. LC-MS (m/z) 286 (M+1).
EXAMPLE 27
Preparation of (Z)-N-(2-amino-4-methylphenyl)-6-(2-(2-((5-fluoro-2-oxoindolin-3-ylidene)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0106]
[0107] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-methylphenyl)-6-(2-aminoethylamino)nicotinamide (299 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (420 mg, 74%) as a yellow solid. LC-MS (m/z) 568 (M+1).
EXAMPLE 28
Preparation of N-(2-amino-4-methylphenyl)-6-(2-(2-(((5-fluoro-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0108]
[0109] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-methylphenyl)-6-(2-aminoethylamino)nicotinamide (299 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (363 mg, 61%) as a red solid. LC-MS (m/z) 596 (M+1).
EXAMPLE 29
Preparation of N-(2-amino-4-methoxyphenyl)-6-chloronicotinamide
[0110]
[0111] 6-Chloronicotinic acid (157.5 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and 4-methoxy-o-phenylenediamine (166 mg, 1.2 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine and extracted with 200 ml of ethyl acetate. The ethyl acetate was removed under vacuum. To the residue was added 5 ml of absolute ethanol. The solids were collected by vacuum filtration, washed with absolute ethanol and dried under vacuum to give the title compound (144 mg, 52% yield) as a brown solid. LC-MS (m/z) 278 (M+1).
EXAMPLE 30
Preparation of N-(2-amino-4-methoxyphenyl)-6-(2-aminoethylamino)nicotinamide
[0112]
[0113] N-(2-Amino-4-methoxyphenyl)-6-chloronicotinamide (277 mg, 1 mmol) and 5 ml of ethylenediamine were heated to 80° C. for 3 hours. The excess ethylenediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (144 mg, 48% yield) as a brown solid. LC-MS (m/z) 302 (M+1).
EXAMPLE 31
Preparation of (Z)-N-(2-amino-4-methoxyphenyl)-6-(2-(2-((5-fluoro-2-oxoindolin-3-ylidene)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0114]
[0115] 5-(5-fFuoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-methoxyphenyl)-6-(2-aminoethylamino)nicotinamide (316 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (478 mg, 82%) as a yellow solid. LC-MS (m/z) 584 (M+1).
EXAMPLE 32
Preparation of N-(2-amino-4-methoxyphenyl)-6-(2-(2-(((5-fluoro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0116]
[0117] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-methoxyphenyl)-6-(2-aminoethylamino)nicotinamide (316 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (397 mg, 65%) as a red solid. LC-MS (m/z) 612 (M+1).
EXAMPLE 33
Preparation of N-(2-amino-4-trifluoromethylphenyl)-6-chloronicotinamide
[0118]
[0119] 6-Chloronicotinic acid (157.5 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and 4-trifluoromethyl-o-phenylenediamine (211 mg, 1.2 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine and extracted with 200 ml of ethyl acetate. The ethyl acetate was removed under vacuum. To the residue was added 5 ml of absolute ethanol. The solids were collected by vacuum filtration, washed with absolute ethanol and dried under vacuum to give the title compound (418 mg, 42% yield) as a brown solid. LC-MS (m/z) 316 (M+1).
EXAMPLE 34
Preparation of N-(2-amino-4-trifluoromethylphenyl)-6-(2-aminoethylamino)nicotinamide
[0120]
[0121] N-(2-Amino-4-trifluoromethylphenyl)-6-chloronicotinamide (316 mg, 1 mmol) and 5 ml of ethylenediamine were heated to 80° C. for 3 hours. The excess ethylenediamine was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (159 mg, 47% yield) as a brown solid. LC-MS (m/z) 340 (M+1).
EXAMPLE 35
Preparation of (Z)-N-(2-amino-4-trifluoromethylphenyl)-6-(2-(2-((5-fluoro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0122]
[0123] 5-(5-Fluoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-trifluoromethylphenyl)-6-(2-aminoethylamino)nicotinamide (356 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (422 mg, 68%) as a yellow solid. LC-MS (m/z) 622 (M+1).
EXAMPLE 36
Preparation of N-(2-amino-4-trifluoromethylphenyl)-6-(2-(2-(((5-fluoro-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0124]
[0125] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-amino-4-trifluorophenyl)-6-(2-aminoethylamino)nicotinamide (356 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (350 mg, 54%) as a red solid. LC-MS (m/z) 650 (M+1).
EXAMPLE 37
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0126]
[0127] 5-(2-Oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (282 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (460 mg, 86%) as a yellow solid. LC-MS (m/z) 536 (M+1).
EXAMPLE 38
Preparation of N-(2-aminophenyl)-6-(2-(2-(((2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0128]
[0129] 2-(((2-Oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (310 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (394 mg, 70%) as a red solid. LC-MS (m/z) 564 (M+1).
EXAMPLE 39
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((5-chloro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0130]
[0131] 5-(5-Chloro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (316 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (444 mg, 77%) as a yellow solid. LC-MS (m/z) 570 (M+1).
EXAMPLE 40
Preparation of N-(2-aminophenyl)-6-(2-(2-(((5-chloro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0132]
[0133] 2-(((5-Chloro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (344 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (376 mg, 63%) as a red solid. LC-MS (m/z) 598 (M+1).
EXAMPLE 41
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((4-methyl-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0134]
[0135] 5-(4-Methyl-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (296 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (445 mg, 81%) as a yellow solid. LC-MS (m/z) 550 (M+1).
EXAMPLE 42
Preparation of N-(2-aminophenyl)-6-(2-(2-(((4-methyl-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0136]
[0137] 2-(((4-Methyl-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (324 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (438 mg, 76%) as a red solid. LC-MS (m/z) 578 (M+1).
EXAMPLE 43
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((5-nitro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0138]
[0139] 5-(5-Nitro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (327 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (383 mg, 66%) as a yellow solid. LC-MS (m/z) 581 (M+1).
EXAMPLE 44
Preparation of N-(2-aminophenyl)-6-(2-(2-(((5-nitro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0140]
[0141] 2-(((5-Nitro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (355 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (450 mg, 74%) as a red solid. LC-MS (m/z) 609 (M+1).
EXAMPLE 45
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((6-methoxy-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0142]
[0143] 5-(6-Methoxy-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (312 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (463 mg, 82%) as a yellow solid. LC-MS (m/z) 566 (M+1).
EXAMPLE 46
Preparation of N-(2-aminophenyl)-6-(2-(2-(((6-methoxy-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0144]
[0145] 2-(((6-Methoxy-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (340 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (397 mg, 67%) as a red solid. LC-MS (m/z) 594 (M+1).
EXAMPLE 47
Preparation of (Z)-N-(2-aminophenyl)-6-(2-(2-((6-trifluoromethyl-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0146]
[0147] 5-(6-Trifluoromethyl-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (350 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (356 mg, 59%) as a yellow solid. LC-MS (m/z) 604 (M+1).
EXAMPLE 48
Preparation of N-(2-aminophenyl)-6-(2-(2-(((6-trifluoromethyl-2-oxoindolin-3-ylidene)-hydrazono)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)ethylamino)nicotinamide
[0148]
[0149] 2-(((6-Trifluoromethyl-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (378 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(2-aminoethylamino)nicotinamide (284 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (341 mg, 54%) as a red solid. LC-MS (m/z) 632 (M+1).
EXAMPLE 49
Preparation of N-(2-aminophenyl)-6-(6-aminohexylamino)nicotinamide
[0150]
[0151] N-(2-Aminophenyl)-6-chloronicotinamide (248 mg, 1 mmol) and 1,6-diaminohexane (5.80 g, 50 mmol) were heated to 80° C. for 3 hours. The excess 1,6-diaminohexane was removed under vacuum. To the residue was added 5 ml of 0.20 M NaOH. The mixture was extracted with 100 ml of ethyl acetate. The ethyl acetate was removed under vacuum to give the title compound (219 mg, 67% yield) as a brown solid. LC-MS (m/z) 328 (M+1).
EXAMPLE 50
Preparation of (Z)-N-(2-aminophenyl)-6-(6-(2-((5-fluoro-2-oxoindolin-3-ylidene)methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)hexylamino)nicotinamide
[0152]
[0153] 5-(5-Fuoro-2-oxo-1,2-dihydro-indol-(3Z)-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (300 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(6-aminohexylamino)nicotinamide (343 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (487 mg, 80%) as a yellow solid. LC-MS (m/z) 610 (M+1).
EXAMPLE 51
Preparation of N-(2-aminophenyl)-6-(6-(2-(((5-fluoro-2-oxoindolin-3-ylidene)hydrazono)-methyl)-3,5-dimethyl-1H-pyrrole-4-carboxamido)hexylamino)nicotinamide
[0154]
[0155] 2-(((5-Fluoro-2-oxoindolin-3-ylidene)hydrazono)methyl)-2,4-dimethyl-1H-pyrrole-4-carboxylic acid (328 mg, 1 mmol) and 8 ml of DMF were stirred at room temperature while 1-Ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (384 mg, 2 mmol), hydroxybenzotriazole (162 mg, 1.2 mmol), triethylamine (404 mg, 4 mmol) and N-(2-aminophenyl)-6-(6-aminohexylamino)nicotinamide (343 mg, 1.05 mmol) were added. The mixture was stirred for 20 hours at room temperature. The mixture was diluted with 400 mL of brine. The solids were collected by vacuum filtration, washed with water and dried under vacuum to give the title compound (427 mg, 67%) as a red solid. LC-MS (m/z) 638 (M+1).
EXAMPLE 52
In Vivo Inhibition of Receptor Tyrosine Kinase Activity Via Ligand-Dependent Cell Proliferation Assay by Compounds from Formula (I)
[0156]
[0000]
GI 50 nM
GI 50 nM
GI 50 nM
(c-Kit
(PDGF
(VEGF
Example
ligand-dependent
ligand-dependent
ligand-dependent
(compound)
cell proliferation)
cell proliferation)
cell proliferation)
3
126
>1000
<1
4
>1000
>1000
1
6
46
>1000
9
7
>1000
>1000
387
9
32
105
12
10
>1000
>1000
568
13
151
>1000
7
14
>1000
>1000
201
16
105
>1000
39
17
>1000
>1000
460
19
42
>1000
81
20
>1000
>1000
330
[0157] Measurement of in vivo inhibition on receptor ligand-dependent cell proliferation:
[0158] PDGF dependent cell proliferation:
[0159] NIH-3T3 mouse fibroblasts cell line engineered to stably express human PDGFRβ was constructed and used to evaluate PDGF dependent cell proliferation. PDGFRβ NIH-3T3 cells were plated into 96-well plates at 5,000 per well and incubated with serum-free medium for 24 hours. Compounds and PDGF BB (50 ng/ml) were added and incubated for 72 hours in serum-free medium. The effects on proliferation were determined by addition of MTS reagent (Promega) according to the instruction, incubation for 2 hours at 37° C. in CO 2 incubator, and record the absorbance at 490 nm using an ELISA plate reader.
[0160] VEGF dependent cell proliferation:
[0161] HUVEC cells were plated into 96-well plates at 6,000 per well and incubated with serum-free medium for 2 hours. Compounds and VEGF 165 (50 ng/ml) were added and incubated for 72 hours in serum-free medium. The effects on proliferation were determined by addition of MTS reagent (Promega) according to the instruction, incubation for 2 hours at 37° C. in CO 2 incubator, and record the absorbance at 490 nm using an ELISA plate reader.
[0162] SCF dependent cell proliferation:
[0163] Mo7e cells (SCF dependent) were plated into 96-well plates at 15000 per well and incubated in 1640 medium with 10% FBS and SCF (50 ng/ml) for 24 hours. Compounds were added and incubated for 72 hours at 37° C. in CO 2 incubator. The effects on proliferation were determined by addition of MTS reagent (Promega) according to the instruction, incubation for 2 hours at 37° C. in CO 2 incubator, and record the absorbance at 490 nm using an ELISA plate reader.
EXAMPLE 53
In Vitro Inhibition of Enzyme Activities on 4 Different Receptor Tyrosine Kinases by Compounds from Formula (I)
[0164]
[0000]
Example
IC 50 nM
IC 50 nM
IC 50 nM
IC 50 nM
(compound)
(c-Kit)
(PDGFβ)
(VEGFR2)
(Flt3)
3
157
780
11
76
4
>1000
>1000
12
870
6
76
>1000
45
132
7
>1000
>1000
634
451
9
23
276
35
25
10
>1000
>1000
>1000
>1000
13
534
468
43
63
14
>1000
>1000
324
432
16
242
>1000
72
623
17
>1000
>1000
>1000
>1000
19
65
>1000
157
21
20
>1000
>1000
>1000
>1000
[0165] Measurement of in vitro inhibition on enzyme activity of receptor tyrosine kinase:
[0166] PDGFRα Bioassay:
[0167] This assay is used to measure in vitro kinase activity of PDGFRα in an ELISA assay. Materials and Reagent:
1. Streptavidin coated-96-well-white plate 2. Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100) (Cell Signaling) 3. HRP-labeled anti-mouse IgG (Upstate) 4. HTScan™ Tyrosine Kinase Buffer (4×) 5. DTT (1000×. 1.25 M) 6. ATP (10 mM) 7. FLT3 (Tyr589) Biotinylated Peptide Substrate (Cell Signaling) 8. PDGF Receptor α Kinase (Cell Signaling) 9. Wash Buffer: 1× PBS, 0.05% Tween-20 (PBS/T) 10. Bovine Serum Albumin (BSA) 11. Stop Buffer: 50 mM EDTA, pH 8 12. Enhanced chemiluminescence (ECL) (Amersham)
[0180] Procedure for performing the assay in 96-well plate:
1. Add 10 μl 10 mM ATP to 1.25 ml 6 μM substrate peptide. Dilute the mixture with dH 2 0 to 2.5 ml to make 2× ATP/substrate cocktail ([ATP]=400 μM, [substrate]=3 μm). 2. Immediately transfer enzyme from −80° C. to ice. Allow enzyme to thaw on ice. 3. Microcentrifuge briefly at 4° C. to bring liquid to the bottom of the vial. Return immediately to ice. 4. Add 10 μl of DTT (1.25 M) to 2.5 ml of 4× HTScan™ Tyrosine Kinase Buffer (240 mM HEPES pH 7.5, 20 mM MgCl 2 , 20 mM MnCl 2 , 12 μM Na 3 VO 4 ) to make DTT/Kinase buffer. 5. Transfer 1.25 ml of DTT/Kinase buffer to enzyme tube to make 4× reaction cocktail ([enzyme]=4 ng/μL in 4× reaction cocktail). 6. Incubate 12.5 μl of the 4× reaction cocktail with 12.5 μl/well of prediluted compound of interest (usually around 10 μM) for 5 minutes at room temperature. 7. Add 25 μl of 2× ATP/substrate cocktail to 25 μl/well preincubated reaction cocktail/compound. Final Assay Conditions for a 50 μl Reaction:
60 mM HEPES pH 7.5 5 mM MgCl 2 5 mM MnCl 2 3 μM Na 3 VO 4 1.25 mM DTT 200 μM ATP 1.5 μM peptide 50 ng PDGF Receptor Kinase
1. Incubate reaction plate at room temperature for 30 minutes. 2. Add 50 μl/well Stop Buffer (50 mM EDTA, pH 8) to stop the reaction. 3. Transfer 25 μl of each reaction and 75 μl dH 2 O/well to a 96-well streptavidin-coated plate and incubate at room temperature for 60 minutes. 11. Wash three times with 200 μl/well PBS/T 12. Dilute primary antibody, Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100), 1:1000 in PBS/T with 1 % BSA. Add 100 μl/well of primary antibody. 13. Incubate at room temperature for 60 minutes. 14. Wash three times with 200 μl/well PBS/T 15. Dilute HRP labeled anti-mouse IgG 1:500 in PBS/T with 1% BSA. Add 100 μl/well diluted antibody. 16. Incubate at room temperature for 30 minutes. 17. Wash five times with 200 μl/well PBS/T. 18. Add 100 μl/well ECL Solution. 19. Detect luminescence with appropriate Plate Reader.
[0208] VEGFR1 Bioassay
[0209] This assay is used to measure in vitro kinase activity of VEGFR1 in an ELISA assay.
[0210] Materials and Reagent:
1. Streptavidin coated, 96-well, white plate 2. Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100) (Cell Signaling) 3. HRP-labeled anti-mouse IgG (Upstate) 4. HTScan™ Tyrosine Kinase Buffer (4×) 5. DTT (1000×. 1.25 M) 6. ATP (10 mM) 7. Gastrin Precursor (Tyr87) Biotinylated Peptide Substrate (Cell Signaling) 8. VEGF Receptor 1 Kinase (recombinant, human) (Cell Signaling) 9. Wash Buffer: 1× PBS, 0.05% Tween-20 (PBS/T) 10. Bovine Serum Albumin (BSA) 11. Stop Buffer: 50 mM EDTA pH 8 12. Enhanced chemiluminescence (ECL) (Amersham)
[0223] Procedure for performing the assay in 96-well plate:
1. Add 10 μl 10 mM ATP to 1.25 ml 6 μM substrate peptide. Dilute the mixture with dH 2 0 to 2.5 ml to make 2× ATP/substrate cocktail ([ATP]=400 μM, [substrate]=3 μm). 2. Immediately transfer enzyme from −80° C. to ice. Allow enzyme to thaw on ice. 3. Microcentrifuge briefly at 4° C. to bring liquid to the bottom of the vial. Return immediately to ice. 4. Add 10 μl of DTT (1.25 M) to 2.5 ml of 4× HTScan™ Tyrosine Kinase Buffer (240 mM HEPES pH 7.5, 20 mM MgCl 2 , 20 mM MnCl 2 , 12 μM Na 3 VO 4 ) to make DTT/Kinase buffer. 5. Transfer 1.25 ml of DTT/Kinase buffer to enzyme tube to make 4× reaction cocktail ([enzyme]=4 ng/μL in 4× reaction cocktail). 6. Incubate 12.5 μl of the 4× reaction cocktail with 12.5 μl/well of prediluted compound of interest (usually around 10 μM) for 5 minutes at room temperature. 7. Add 25 μl of 2× ATP/substrate cocktail to 25 μl/well preincubated reaction cocktail/compound. Final Assay Conditions for a 50 μl Reaction:
60 mM HEPES pH 7.5 5 mM MgCl 2 5 mM MnCl 2 3 μM Na 3 VO 4 1.25 mM DTT 200 μM ATP 1.5 μM peptide 100 ng VEGFR1 Kinase
8. Incubate reaction plate at room temperature for 30 minutes. 9. Add 50 μl/well Stop Buffer (50 mM EDTA, pH 8) to stop the reaction. 10. Transfer 25 μl of each reaction and 75 μl dH 2 O/well to a 96-well streptavidincoated plate and incubate at room temperature for 60 minutes. 11. Wash three times with 200 μl/well PBS/T 12. Dilute primary antibody, Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100), 1:1000 in PBS/T with 1 % BSA. Add 100 μl/well of primary antibody. 13. Incubate at room temperature for 60 minutes. 14. Wash three times with 200 μl/well PBS/T 15. Dilute HRP labeled anti-mouse IgG 1:500 in PBS/T with 1% BSA. Add 100 μl/well diluted antibody. 16. Incubate at room temperature for 30 minutes. 17. Wash five times with 200 μl/well PBS/T. 18. Add 100 μl/well ECL Solution. 19. Detect luminescence with appropriate Plate Reader.
[0251] c-KIT Bioassay
[0252] This assay is used to measure in vitro kinase activity of c-KIT in an ELISA assay.
[0253] Materials and Reagent:
1. Streptavidin coated, 96-well, white plate 2. Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100) (Cell Signaling) 3. HRP-labeled anti-mouse IgG (Upstate) 4. HTScan™ Tyrosine Kinase Buffer (4×) 5. DTT (1000×. 1.25 M) 6. ATP (10 mM) 7. KDR (Tyr996) Biotinylated Peptide Substrate (Cell Signaling) 8. c-KIT Kinase (recombinant, human) (Cell Signaling) 9. Wash Buffer: 1× PBS, 0.05% Tween-20 (PBS/T) 10. Bovine Serum Albumin (BSA) 11. Stop Buffer: 50 mM EDTA pH 8 12. Enhanced chemiluminescence (ECL) (Amersham)
[0266] Procedure for performing the assay in 96-well plate:
1. Add 10 μl 10 mM ATP to 1.25 ml 6 μM substrate peptide. Dilute the mixture with dH 2 0 to 2.5 ml to make 2× ATP/substrate cocktail ([ATP]=40 μM, [substrate]=3 μm). 2. Immediately transfer enzyme from −80° C. to ice. Allow enzyme to thaw on ice. 3. Microcentrifuge briefly at 4° C. to bring liquid to the bottom of the vial. Return immediately to ice. 4. Add 10 μl of DTT (1.25 M) to 2.5 ml of 4× HTScan™ Tyrosine Kinase Buffer (240 mM HEPES pH 7.5, 20 mM MgCl 2 , 20 mM MnCl 2 , 12 μM Na 3 VO 4 ) to make DTT/Kinase buffer. 5. Transfer 1.25 ml of DTT/Kinase buffer to enzyme tube to make 4× reaction cocktail ([enzyme]=4 ng/μL in 4× reaction cocktail). 6. Incubate 12.5 μl of the 4× reaction cocktail with 12.5 μl/well of prediluted compound of interest (usually around 10 μM) for 5 minutes at room temperature. 7. Add 25 μl of 2× ATP/substrate cocktail to 25 μl/well preincubated reaction cocktail/compound. Final Assay Conditions for a 50 μl Reaction:
60 mM HEPES pH 7.5 5 mM MgCl 2 5 mM MnCl 2 3 μM Na 3 VO 4 1.25 mM DTT 20 μM ATP 1.5 μM peptide 100 ng c-KIT Kinase
8. Incubate reaction plate at room temperature for 30 minutes. 9. Add 50 μl/well Stop Buffer (50 mM EDTA, pH 8) to stop the reaction. 10. Transfer 25 μl of each reaction and 75 μl dH 2 O/well to a 96-well streptavidincoated plate and incubate at room temperature for 60 minutes. 11. Wash three times with 200 μl/well PBS/T 12. Dilute primary antibody, Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100), 1:1000 in PBS/T with 1% BSA. Add 100 μl/well of primary antibody. 13. Incubate at room temperature for 60 minutes. 14. Wash three times with 200 μl/well PBS/T 15. Dilute HRP labeled anti-mouse IgG 1:500 in PBS/T with 1% BSA. Add 100 μl/well diluted antibody. 16. Incubate at room temperature for 30 minutes. 17. Wash five times with 200 μl/well PBS/T. 18. Add 100 μl/well ECL Solution. 19. Detect luminescence with appropriate Plate Reader.
[0294] Flt3 Bioassay
[0295] This assay is used to measure in vitro kinase activity of Flt3 in an ELISA assay.
[0296] Materials and Reagent:
1. Streptavidin coated, 96-well, white plate 2. Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100) (Cell Signaling) 3. HRP-labeled anti-mouse IgG (Upstate) 4. HTScan™ Tyrosine Kinase Buffer (4×) 5. DTT (1000×. 1.25 M) 6. ATP (10 mM) 7. KDR (Tyr996) Biotinylated Peptide Substrate (Cell Signaling) 8. Flt3 Kinase (recombinant, human) (Cell Signaling) 9. Wash Buffer: 1× PBS, 0.05% Tween-20 (PBS/T) 10. Bovine Serum Albumin (BSA) 11. Stop Buffer: 50 mM EDTA pH 8 12. Enhanced chemiluminescence (ECL) (Amersham)
[0309] Procedure for performing the assay in 96-well plate:
1. Add 10 μl 10 mM ATP to 1.25 ml 6 μM substrate peptide. Dilute the mixture with dH 2 0 to 2.5 ml to make 2× ATP/substrate cocktail ([ATP]=400 μM, [substrate]=3 μm). 2. Immediately transfer enzyme from −80° C. to ice. Allow enzyme to thaw on ice. 3. Microcentrifuge briefly at 4° C. to bring liquid to the bottom of the vial. Return immediately to ice. 4. Add 10 μl of DTT (1.25 M) to 2.5 ml of 4× HTScan™ Tyrosine Kinase Buffer (240 mM HEPES pH 7.5, 20 mM MgCl 2 , 20 mM MnCl 2 , 12 μM Na 3 VO 4 ) to make DTT/Kinase buffer. 5. Transfer 1.25 ml of DTT/Kinase buffer to enzyme tube to make 4× reaction cocktail ([enzyme]=4 ng/μL in 4× reaction cocktail). 6. Incubate 12.5 μl of the 4× reaction cocktail with 12.5 μl/well of prediluted compound of interest (usually around 10 μM) for 5 minutes at room temperature. 7. Add 25 μl of 2× ATP/substrate cocktail to 25 μl/well preincubated reaction cocktail/compound. Final Assay Conditions for a 50 μl Reaction:
60 mM HEPES pH 7.5 5 mM MgCl 2 5 mM MnCl 2 3 μM Na 3 VO 4 1.25 mM DTT 200 μM ATP 1.5 μM peptide 10 units Flt3 Kinase
8. Incubate reaction plate at room temperature for 30 minutes. 9. Add 50 μl/well Stop Buffer (50 mM EDTA, pH 8) to stop the reaction. 10. Transfer 50 μl of each reaction and 50 μl dH 2 O/well to a 96-well streptavidincoated plate and incubate at room temperature for 60 minutes. 11. Wash three times with 200 μl/well PBS/T 12. Dilute primary antibody, Phospho-Tyrosine Monoclonal Antibody (P-Tyr-100), 1:1000 in PBS/T with 1% BSA. Add 100 μl/well of primary antibody. 13. Incubate at room temperature for 60 minutes. 14. Wash three times with 200 μl/well PBS/T 15. Dilute HRP labeled anti-mouse IgG 1:500 in PBS/T with 1% BSA. Add 100 μl/well diluted antibody. 16. Incubate at room temperature for 30 minutes. 17. Wash five times with 200 μl/well PBS/T. 18. Add 100 μl/well ECL Solution. 19. Detect luminescence with appropriate Plate Reader.
[0337] The assays to measure enzyme activity of all other receptor tyrosine kinases are essentially identical to that as exemplified in the case of VEGF, PDGF, c-Kit or Flt3 receptor tyrosine kinase assay except specific receptor tyrosine kinase reagent may be used in a given receptor tyrosine kinase context.
EXAMPLE 54
In Vitro Inhibition of Total HDAC Enzyme Activity and In Vivo Inhibition of HDAC Subtype Activity by Compounds from Formula (I)
[0338]
[0000]
Class I
HDAC3
HDAC4/5
HDAC
(GDF11
(MEF2
HDAC7
% inhibition
(P21 reporter
reporter
reporter
(Nur77 reporter
of total
assay)
assay)
assay)
assay)
HDAC
% Max
% Max
% Max
% Max
enzyme
Resp of
Resp of
Resp of
Resp of
Example
activity at
EC 50
CS055
EC 50
CS055
EC 50
CS055
EC 50
CS055
(compound)
30 μM
μM
at 3 μM
μM
at 3 μM
μM
at 3 μM
μM
at 3 μM
CS055
46.2
3.5
100.0
3.2
100.0
15.1
100.0
6.8
100.0
SAHA
95.7
0.5
304.1
0.8
317.9
1.2
427.3
3.0
514.9
3
9.20
2.3
131.7
1.9
106.2
2.2
83.2
2.9
113.5
4
6.90
nd
3.3
nd
2.4
nd
4.9
nd
3.9
6
12.50
2.5
74.6
1.0
75.6
1.0
44.2
2.5
88.1
7
7.80
nd
6.2
nd
6.3
nd
2.6
nd
12.4
9
6.30
13.4
89.1
15.5
81.4
20.0
53.6
13.2
88.7
10
6.10
nd
7.3
nd
8.3
nd
12.8
nd
13.2
13
−2.60
nd
2.1
nd
1.8
nd
0.5
nd
6.4
14
1.00
nd
2.1
nd
2.0
nd
2.4
nd
4.5
16
6.70
nd
2.5
nd
1.8
nd
−0.2
nd
6.5
17
4.00
nd
3.4
nd
3.8
nd
10.8
nd
3.5
19
7.30
nd
2.3
nd
2.0
nd
1.9
nd
6.0
20
3.50
nd
2.8
nd
4.1
nd
16.3
nd
1.0
nd*: not determined
CS055: Chidamide is a HDACi currently in clinic development against cancers with good efficacy and toxicity profile from Chipscreen Biosciences
[0339] Measurement of in vitro inhibition of total HDAC enzyme activity:
The in vitro inhibition of total HDAC enzyme was determined by HDAC Fluorimetric Assay/Drug Discovery Kit (BIOMOL) according to manufacture's instruction. 1. Add Assay buffer, diluted trichostatin A or test inhibitor to appropriate wells of the microtiter plate. Following table lists examples of various assay types and the additions required for each test.
[0000]
Fluor
HeLa Extract
Inhibitor
de Lys ™
Sample
Assay Buffer
(Dilution)
(5x)
Substrate (2x)
Blank
25
μl
0
0
25 μl
(No Enzyme)
Control
10
μl
15
μl
0
25 μl
Trichostatin A
0
15
μl
10
μl
25 μl
Test Sample
0
15
μl
10
μl
25 μl
2. Add diluted HeLa extract or other HDAC sample to all wells except those that are to be “No Enzyme Controls” (Blank).
3. Allow diluted Fluor de Lys™ Substrate and the samples in the microtiter plate to equilibrate to assay temperature (25° C.).
4. Initiate HDAC reactions by adding diluted substrate (25 μl) to each well and mixing thoroughly.
5. Allow HDAC reactions to proceed for desired length of time and then stop them by addition of Fluor de Lys™ Developer (50 μl). Incubate plate at room temperature (25° C.) for 10-15 min.
6. Read samples in a microtiter-plate reading fluorimeter capable of excitation at a wavelength in the range 350-380 nm and detection of emitted light in the range 440-460 nm.
[0347] Measurement of in vivo inhibition of HDAC subtype activity:
[0348] HDAC subtype selectivity inhibition assay of tested compounds was carried out by several reporter gene assays experiments. Briefly, HeLa cells were seeded in 96-well plates the day before transfection to give a confluence of 50-80%. Cells were transfected with one of reporter gene plasmid containing a promoter sequence or response element upstream of a luciferase gene construct using FuGene6 transfection reagent according to the manufacturer's instruction (Roche). The promoters or response elements including p21-promoter, gdf11-promoter, MEF-binding element (MEF2), Nur77-promoter were fused upstream to the luciferase gene reporter construct. For normalizing the transfection efficiency, a GFP expression plasmid was cotransfected. Cells were allowed to express protein for 24 hours followed by addition of individual compounds or the vehicle (DMSO). 24 hours later the cells were harvested, and the luciferase assay and GFP assay were performed using corresponding assay kits according to the manufacturer's instructions (Promega).
EXAMPLE 55
In Vivo Anti-Proliferation by Compounds from Formula (I)
[0349]
[0000]
GI 50
GI 50
μM
GI 50
GI 50
GI 50
GI 50
μM in
GI 50
GI 50
GI 50
GI 50
GI 50
GI 50
in
μM
μM in
μM
Example
μM in
Hut-
μM in
μM in
μM in
μM in
μM in
μM in
Bel-
in
MDA-M
in
(compound)
HL60
78
Raji
Jurkat
U937
Ramos
A549
HeLa
7402
MCF7
B-231
HCT-8
3
4.15
1.77
3.45
>60
>60
>60
>60
>60
>60
>60
>60
>60
4
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
6
>60
>60
3.45
>60
>60
>60
>60
>60
>60
>60
>60
>60
7
7.91
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
9
1.27
1.67
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
10
6.28
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
13
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
14
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
16
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
17
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
19
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
20
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
>60
CS055
1.00
1.69
9.29
3.79
2.50
>60
13.75
21.29
28.06
>60
36.15
>60
Sorafinib
1.28
12.54
4.15
16.91
4.06
1.51
13.75
30.77
9.73
9.51
4.25
5.35
Sutent
1.73
4.06
5.47
7.05
8.28
11.97
14.73
9.29
13.13
7.55
4.66
12.25
Note:
Chidamide is a HDAC inhibitor currently in clinic development against cancers with preference against class I HDAC enzyme; Suten and Sorafinib are two marketed RTK and Ser/Thr kinase inhibitors with broad activity against many different receptor tyrosine or ser/thr kinases
[0350] Measurement of in vivo cell proliferation:
[0351] Tumor cells were trypsinized and plated into 96-well plates at 3,000 per well and incubated in complete medium with 10% FBS for 24 hours. Compounds were added over a final concentration range of 100 μmol/L to 100 nmol/L in 0.1% DMSO and incubated for 72 hours in complete medium. The effects on proliferation were determined by addition of MTS reagent (Promega) according to the instruction, incubation for 2 hours at 37° C. in CO 2 incubator, and record the absorbance at 490 nm using an ELISA plate reader.
[0352] Human Cell lines are listed below:
[0000]
HL-60:
Acute promyelocytic leukemia
Hut-78:
Cutaneous T cell lymphoma
Raji:
Burkitt's lymphoma
Jurkat:
T cell leukemia
U937:
Histiocytic lymphoma
Ramos:
Burkitt's lymphoma
A549:
Non small cell lung carcinoma
HeLa:
Cervix adenocarcinoma
Bel-7402:
Hepatocellular carcinoma
MCF-7:
Mammary gland adenocarcinoma
MDA-MB-231:
Mammary gland adenocarcinoma
HCT-8:
Ileocecal colorectal adenocarcinoma
|
The present invention relates to 2-indolinone derivatives which are capable of inhibiting protein kinases and histone deacetylases. The compounds of this invention are therefore useful in treating diseases associated with abnormal protein kinase activities or abnormal histone deacetylase activities. Pharmaceutical compositions comprising these compounds, methods of treating diseases utilizing pharmaceutical compositions comprising these compounds, and methods of preparing these compounds are also disclosed.
| 2
|
This application is a continuation of 09/733,749 filed Dec. 9, 2000 for TOOL FOR INSTALLING VALVE LOCKS, now U.S. Pat. No. 6,473,965, which is a division of 09/394,483 filed Sep. 11, 1999, now U.S. Pat. No. 6,219,896, for TOOLS FOR INSTALLING VALVE LOCKS, fully incorporated herein by this reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of automotive mechanics and specifically relates to a tool for installing valve locks on a valve stem. The valve lock removably secures a valve retainer to the valve stem. The tool typically would be used by an automobile mechanic or by an engine reconditioner.
2. The Prior Art
During the compression and expansion cycles, the valves of a conventional internal combustion engine are forced shut by the high pressure within the cylinder. To implement the intake and exhaust cycles, the valves must be opened at appropriate times, and this is usually accomplished by the use of a cam that pushes against the end of the valve stem, thereby forcing the head of the valve into the combustion chamber. To assure positive operation, a valve spring urges the valve to its closed position, and the cam must overcome the urging of the valve spring to open the valve. Typically, the valve spring is a compression spring. One end of the compression spring bears against a stationary part of the engine, and the other end of the spring bears against a valve spring retainer that is removably secured to the valve stem by a valve lock. Were it not for the valve lock, the compressive force of the valve spring would push the retainer off the end of the valve stem. The retainer must be removably secured to the valve stem to permit assembly and dis-assembly of the valve.
In theory, a nut and washer would suffice to secure the retainer to the valve stem. However, after nearly a century of experience, a specialized type of valve lock is almost universally used. The retainer has a tapered central bore that opens toward the end of the valve stem. The valve stem has an end portion that includes a circumferential groove. The valve lock is a tapered split collar that has an inwardly facing ridge. The ridge engages the circumferential groove of the valve stem and is held in engagement by the taper of the central tapered bore of the retainer. The valve lock is thus jammed between the circumferential groove on the valve stem and the tapered central bore of the retainer, which is urged toward the end of the valve stem by the valve spring.
Although this way of securing the retainer to the valve stem is simple and effective in use, it has proven to be very challenging for most mechanics to take apart and reassemble, which must be done when the valves are ground or the engine is reconditioned.
Part of the difficulty is that the retainer must be drawn back, away from the end of the valve stem against the urging of the valve spring, to expose the valve locks. In contemporary engines, the force exerted by the valve spring is in the range of 60 to 90 pounds, and mere finger pressure generally is not adequate. Another part of the difficulty is that the valve locks are rather small in comparison to the valve stem and are difficult to manipulate. To make matters worse, the valve spring and the retainer are frequently located in a poorly-illuminated and fairly close-fitting recess, which makes the parts somewhat inaccessible.
Large console-type machines are commercially available, but they merely compress the valve springs. They occupy valuable floor space in the shop, and have a high initial cost. It appears that a need exists for a hand tool to facilitate the installing of valve locks.
SUMMARY OF THE INVENTION
The present invention is a hand tool to facilitate the installation of a valve lock into a circumferential groove on a valve stem.
In accordance with the present invention, the tool includes a loader end cap having an end that faces the valve spring retainer when the tool is in use and further includes a central bore extending in the direction of the axis of the valve stem when the tool is in use. A plunger extends through this bore and protrudes beyond the end of the loader end cap. The plunger is biased toward the valve stem and has the same diameter as the valve stem. The valve locks are placed by the user on the protruding cylindrical surface of the plunger, and the axis of the plunger is brought into alignment with the axis of the valve stem. The user then pushes the tool against the valve spring retainer, gradually depressing the retainer by compressing the valve spring, and the end of the valve stem makes contact with the protruding end of the plunger. As the tool is pushed onto the valve stem, the valve stem forces the plunger back into the loader end cap, and the valve locks are pushed onto the valve stem by the loader end cap. The valve locks engage the circumferential groove on the end portion of the valve stem, and as the tool is withdrawn, the retainer advances toward the end of the valve stem also engaging the valve locks and preventing them from coming out of the circumferential groove.
The tool of the present invention permits the valve locks to be installed in a valve in approximately 15 seconds per valve, which is one-third to one-quarter of the time previously required, depending on the mechanic. The hand tool of the present invention occupies no floor space in the shop, and costs only about one-tenth of the cost of the large console-type machines currently on the market.
The operation of the tool as well as its construction will be described in detail in the following paragraphs with the help of the accompanying drawings. The drawings show a preferred embodiment of the invention, but should not be regarded as limiting the scope of the invention.
The novel features which are believed to be characteristic of the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which several preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view partly in cross section showing a type of valve assembly used in the prior art;
FIG. 2 is a side elevational exploded view partly in cross section showing the removal of the valve locks from the valve stem following compression of the valve spring in the prior art assembly of FIG. 1 ;
FIG. 3 is a front perspective view of a valve lock of a type used in the prior art and shown enlarged relative to FIGS. 1 and 2 ;
FIG. 4 is a perspective view showing a preferred embodiment of the hand tool of the present invention;
FIG. 5 is a fractional side elevational view partly in cross section showing a valve assembly and the tool of the present invention after the tool has been prepared for use but before the tool has been applied to the valve assembly;
FIG. 6 is a fractional side elevational view partly in cross section showing the tool and the valve assembly at the instant when the end of the valve stem first makes contact with the end of the plunger of the tool;
FIG. 7 is a fractional side elevational view partly in cross section showing the tool and the valve assembly after the tool has been used to push back the valve retainer to a greater extent than in FIG. 6 , and in which the valve locks have been pushed onto the valve stem;
FIG. 8 is a fractional side elevational view partly in cross section showing the tool and the valve assembly after the valve retainer has been pushed back to a greater extent than in FIG. 7 , and in which the valve locks have become seated in the circumferential groove of the valve stem;
FIG. 9 is a fractional side elevational view partly in cross section showing the tool and the valve assembly as the tool is being withdrawn from the valve assembly;
FIG. 10 is a fractional side elevational view partly in cross section showing the tool and the valve assembly with the tool further withdrawn than in FIG. 9 and in which the valve spring retainer engages the valve locks;
FIG. 11 is a fractional side elevational view partly in cross section showing the tool and the valve assembly after the tool has been withdrawn from the valve assembly; and,
FIG. 12 is a fractional side elevational view partly in cross section and enlarged, showing a preferred embodiment of the tool in greater detail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a typical valve assembly of a type used in a contemporary internal combustion engine. The head 12 of the valve forms a movable portion of the wall 14 of the combustion chamber 16 . FIG. 1 shows the valve in its closed position, and the valve opens when it is moved in the direction indicated by the arrow. This motion is produced by a cam (not shown) that bears against the end 18 of the valve stem 20 .
The head 12 of the valve is biased into its closed position by the valve spring 22 , which is a compression spring. One end 24 of the valve spring bears against a fixed portion 26 of the engine. The other end 28 pushes against the valve spring retainer 30 which is attached to the valve stem 20 .
The valve spring retainer 30 is removably attached to the valve stem 20 by two valve locks 32 and 34 , which are shown diagrammatically in FIG. 2 ; a single valve lock is shown greatly enlarged and in full detail in FIG. 3 . As best seen in FIG. 3 , each valve lock includes a cylindrical inwardly-facing surface 36 , a tapered outwardly-facing surface 38 , and a ridge 40 that protrudes inwardly from the surface 36 .
The valve stem 20 includes an end portion 42 into which a circumferential groove 44 has been formed. The valve spring retainer 30 includes a tapered central bore 46 .
FIG. 1 shows the valve stem 20 , the valve locks 32 and 34 and the valve spring retainer 30 in their normal assembled configuration. In FIG. 2 the valve spring retainer 30 is shown drawn back from the end 18 of the valve stem to permit removal of the valve locks 32 and 34 and subsequent dis-assembly of the valve spring retainer 30 and the valve spring 22 .
From FIGS. 1 , 2 and 3 it is seen that the ridge 40 of each valve lock engages the circumferential groove 44 of the valve stem 20 , and the valve locks 32 and 34 are forced radially inward by the tapered central bore 46 of the valve spring retainer 30 which bears against the tapered outwardly-facing surfaces 38 of the valve locks, the valve spring retainer 30 being pushed toward the end 18 of the valve stem by the valve spring 22 .
As mentioned above, the assembly of FIG. 1 is typically located in a recessed portion of the engine and therefore is not easily accessable to most tools. Typically the valve spring is quite stiff and cannot be compressed sufficiently by mere finger pressure to permit the valve locks to be disengaged. Also, typically the valve locks are relatively small, on the order of 6 millimeters in length and 8 millimeters in diameter. The combined result of these factors is to make it difficult to disassemble and to re-assemble the valve assembly.
In an attempt to solve this acute problem, large console-type machines have been developed to support the cylinder head while simultaneously pressing on the valve spring retainers to permit the valve locks to be exposed. These machines typically occupy six square feet of floor space, and they provide no help in handling the valve locks.
In contrast with such large console-type machines, the present invention is a lightweight hand-held tool that is adapted not only to compress the valve spring, but also to set the valve locks into engagement with the circumferential groove of the valve stem. FIG. 4 shows an external view of the tool of the present invention, and FIGS. 5-11 show successive stages in its operation.
FIG. 4 is a perspective view showing the exterior of the hand tool of the present invention. The tool includes a handle 48 affixed to a hollow body 50 having an end 52 and a central axis 54 . A knob 56 is used for adjusting the tool and in replacing certain internal parts to adapt the tool for use with various engines. The knob 56 is attached to a threaded bolt (not shown in FIG. 4 ) that extends through the slot 58 .
FIG. 5 shows the components of the valve assembly discussed above as well as certain essential elements of the tool. These include the hollow body 50 , a loader end cap 60 affixed to the hollow body 50 , having a central bore 62 , and having an end 64 . A plunger 66 having a head 70 also includes a cylindrical body 68 that extends through the central bore 62 of the loader end cap 60 and fits therein in a loose sliding fit. When the head 70 of the plunger is in contact with the loader end cap, as in FIGS. 5 and 6 , an end portion 72 of the plunger extends beyond the end 64 of the loader end cap. The plunger terminates in an end 74 .
The head 70 of the plunger 66 is biased toward the loader end cap 60 by the plunger biasing means 76 , which is a compression spring. The spring 76 is contained within a loader body 78 .
FIG. 5 shows the condition of the valve assembly and of the tool immediately prior to use. The valve spring 22 has been set in place over the valve stem 20 , and the valve spring retainer 30 is positioned at the end of the valve spring 22 . The user has placed the valve locks 32 and 34 on the cylindrical surface of the protruding end portion 72 of the plunger 66 . The means used to prevent the valve locks from filling off the protruding end of the plunger will be described in greater detail below.
As indicated in FIG. 5 , the user has manipulated the tool to bring the central axis 54 into coincidence with the central axis 80 of the valve stem.
Next, as shown in FIG. 6 , the user pushes the tool against the valve spring retainer 30 , compressing the valve spring 22 , permitting the tool to advance toward the valve stem sufficiently that the end 18 of the valve stem makes contact with and coincides with the end 74 of the plunger 66 .
As the user continues to advance the tool, the end 18 of the valve stem pushes the plunger 66 into the loader end cap 60 against the urging of the spring 76 , as shown in FIG. 7 . The end 64 of the loader end cap 60 pushes the valve locks 32 and 34 along the end portion 72 of the plunger and thereafter onto the valve stem 20 .
As the user continues to advance the tool, as shown in FIG. 8 , the valve locks 32 and 34 engage the circumferential groove 44 of the valve stem.
Thereafter, the user draws the tool away from the valve stem as indicated in FIG. 9 until, as shown in FIG. 10 , the advancing valve spring retainer 30 engages the valve locks 32 and 34 . The tapered central bore 46 of the valve spring retainer 30 presses against the valve locks, pushing them radially inward into the circumferential groove 44 and preventing further movement of the valve spring retainer.
Finally, as shown in FIG. 11 , the tool is removed from the valve spring retainer and the task of seating the valve locks 32 and 34 has been completed.
From the above description it can be recognized that there exists a need for some means for keeping the valve locks 32 and 34 in contact with the end portion 72 of the plunger in the positions shown in FIGS. 5 and 6 , and in contact with the end portion 42 of the valve stem, as in FIG. 7 . If one or both of the valve locks were to fall off the protruding end portion 72 of the plunger while the tool is being brought into position, the valve lock might fall into the engine or onto the floor, and retrieving it could be time consuming.
In accordance with the present invention, several ways of keeping the valve locks in contact with the plunger have been devised, and they will now be discussed.
FIG. 12 is an enlarged fraction of FIG. 6 . In FIG. 12 , the central axis 80 of the valve stem is shown oriented vertically because in practice the valve stem is typically oriented approximately vertically. This permits the user of the tool to use his weight in pushing down on the tool to compress the valve spring. In the preferred embodiment shown in FIG. 12 , the plunger 82 is composed of a non-magnetic material such as non-magnetic stainless steel, aluminum, brass, or nylon. The plunger 82 includes a hollow bore that extends almost to the protruding end of the plunger. A powerful cylindrical-shaped permanent magnet 86 is secured to the end of the hollow bore 84 by an adhesive. The north and south poles of the magnet are aligned with the central axis of the bore 84 . The loader end cap 60 is composed of a ferromagnetic material, as are the valve locks and the valve stem. In the preferred embodiment, the permanent magnet 86 is composed of a rare earth alloy, which results in an extremely strong magnetic field. The magnetic field attracts the valve locks to the surface of the plunger thereby preventing the valve locks from falling away as the tool is being brought into position.
As indicated in FIGS. 6 , 7 and 8 , as the user pushes the tool against the valve spring retainer 30 , the latter yields and is depressed with respect to the end 18 of the valve stem. Thus, the valve stem pushes the plunger upward, as seen in FIG. 12 , so that the permanent magnet 86 is carried into the ferromagnetic loader end cap 60 . Because of its ferromagnetism, the loader end cap provides a preferred path for the magnetic lines of flux, which disengage from the valve locks thereby releasing them.
In a first alternative embodiment, the plunger is composed of a ferromagnetic material and is permanently magnetized. The magnetism retains the valve locks against the protruding end of the plunger. In addition, the permanently magnetized plunger magnetizes the end portion 42 of the valve stem, and when the plunger is retracted into the loader end cap, the valve locks are retained in contact with the valve stem by the magnetism.
In a second alternative embodiment, a viscous paste is applied to the protruding end of the plunger, and if necessary to the end portion 42 of the valve stem. The viscous paste may be a grease or a petroleum jelly.
As suggested by FIG. 12 , at the instant the ridges 40 of the valve locks seat in the circumferential groove, the valve spring retainer 30 must be sufficiently far down along the valve stem to permit the valve locks to move to their final position. Thus, the distance between the end 64 of the loader end cap 60 and the end 52 of the hollow body must exceed some critical dimension. This critical dimension varies from one engine to the next, because the valve spring retainers and valve stems have different shapes from one engine to the next. In accordance with the present invention, the distance between the end 52 of the hollow body of the tool and the end 64 of the loader end cap is set for a particular engine by inserting a loader body 88 of appropriate length into the hollow body 50 of the tool. For a particular engine, the user must select the appropriate loader body 88 and insert it into the hollow body 50 of the tool along with a loader end cap 60 that has a central bore 62 equal in diameter to the diameter of the valve stem to be worked on.
Thus, there has been described a preferred embodiment and alternative embodiments of the tool of the present invention. The tool greatly expedites the installation of the valve locks, and is considerably less expensive than equipment previously used for installing the valve locks.
The foregoing detailed description is illustrative of several embodiments of the invention, and it is to be understood that additional embodiments thereof will be obvious to those skilled in the art. The embodiments described herein together with those additional embodiments are considered to be within the scope of the invention.
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A hand tool that greatly expedites the installation of the valve locks that secure a valve spring retainer to the free end of a valve stem. The valve locks include an inwardly extending ridge that engages a circumferential groove that extends around an end portion of the valve stem. The valve lock is retained in this position by a tapered central bore of the valve spring retainer that produces an inward clamping force on the valve lock. The tool includes a plunger having a diameter equal to the diameter of the valve stem. The user positions the valve locks on the protruding cylindrical surface of the plunger, where they are held by magnetic attraction. The user pushes the end of the tool against the valve spring retainer, thereby compressing the valve spring so that the valve stem pushes the plunger into a close-fitting loader end cap until the valve locks are transferred to the valve stem and into engagement with the circumferential groove.
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FIELD OF INVENTION
[0001] The invention relates generally to the field of oil and gas production. More specifically, the present disclosure relates to a device and method for affixing together members to be disposed downhole with two or more opposing wedge like members.
BRIEF DESCRIPTION OF DRAWINGS
[0002] Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
[0003] FIG. 1 illustrates an exploded perspective view of an embodiment of a stop collar assembly.
[0004] FIG. 2 is a perspective view of an assembled embodiment of the assembly of FIG. 1 .
[0005] FIG. 3 depicts a side view of an embodiment of a stop collar assembly of FIG. 1 on a downhole tool.
[0006] FIG. 4 is a plot of load test results for a prior art stop ring and stop collars with different beveled edges.
[0007] While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
[0008] The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. For the convenience in referring to the accompanying figures, directional terms are used for reference and illustration only. For example, the directional terms such as “upper”, “lower”, “above”, “below”, and the like are being used to illustrate a relational location.
[0009] It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
[0010] FIG. 1 provides an exploded view of one example of a stop collar assembly 20 in accordance with the present disclosure. The stop collar assembly 20 comprises annular rings 22 , 24 having beveled surfaces 23 , 25 on their inner diameters. The beveled surfaces 23 , 25 lie at an angle C with respect to the annular rings 22 , 24 axis A x . The annular rings 22 , 24 also include apertures or passages 27 radially formed therethrough. The passages 27 may be threaded and sized to receive set screws 26 within the passages 27 . Adjacent the annular rings 22 , 24 is a gripping wedge ring 28 , shown in this embodiment as having a split section 33 . The gripping wedge ring 28 outer surface includes a ridge at about its mid-section and is profiled away from the ridge at an angle B. Angle B and angle C can be substantially equal or at different values. The ring inner surface 31 may optionally be textured to increase its coefficient of friction. Shown adjacent the ring 24 is an optional sleeve 32 for housing the rings 22 , 24 . The sleeve 32 is provided with elongated slots 34 so the set screws 26 can be externally accessed.
[0011] FIG. 2 provides a perspective view of an assembled embodiment of the stop collar assembly 20 . In FIG. 2 the gripping wedge ring 28 resides coaxially within the sleeve 32 and stacked between the annular stop rings 22 , 24 on opposite sides of the wedge ring 28 . Set screws 26 extend through the slots 34 and into the passages 27 . The slot 34 is elongated along the axial direction of the sleeve 32 thereby allowing the set screw 26 to laterally move within the sleeve 32 body.
[0012] FIG. 3 is a side view of a downhole tool 36 employing a centralizer 40 combined with a stop collar assembly 20 . The centralizer 40 comprises a pair of circular base members 42 , 43 around the downhole tool 36 housing 38 . Centralizer arms 44 pivotingly attach on one end to a first base member 42 and on the other end of the arm 44 to the second base member 43 . As is known, the arms 44 bow out in their midsection into contacting engagement with the inner circumference of a tubular 50 , such as casing or other downhole tubing. The centralizer 40 maintains the downhole tool 36 a set distance from the walls of the tubular 50 . When the tool 36 is stationary in the tubular 50 , the tubular 50 walls exert a radially inward force on the arms 44 resulting in opposing lateral forces pushing the base members 42 , 43 apart. When the tool 36 is being pushed into the tubular 50 its walls tangentially rub against the arms 44 urging the centralizer 40 upward on the tool 36 . This loads the base member 43 against the lower stop collar 20 . Similarly, when pulling the tool 36 from within the tubular 50 , the arms 44 rub against the tubular 50 walls resulting in the base member 42 transferring the arm 44 and tubular 50 wall frictional force against the upper stop collar 20 .
[0013] In the example of use depicted in FIG. 3 , the transferred frictional force between the arms 44 and tubing 50 wall (as illustrated by arrow AF) pushes the anchor 43 against the stop collar assembly 20 . The centralizer anchor 43 is in contact with the annular ring 22 of the collar assembly 20 . The set screws 26 are illustrated tightened through the annular ring 22 and against the housing 38 outer surface to provide sufficient anchoring force for the ring 22 onto the housing 38 . However, in some situations, the force AF may exceed the compression and friction forces of the set screws 26 on the housing 38 and may axially move the annular rings 22 toward the adjacent gripping wedge ring 28 . This further engages the beveled surface 23 against the wedge ring's 28 profile thereby further compressing the wedge ring 28 against the housing 38 . Further engaging the beveled surface 23 over the wedge ring 28 profile correspondingly increases the compression force applied to the housing 38 by the wedge ring 28 . Ultimately, the compressive force exceeds the axial force AF thereby preventing further lateral movement of the annular ring 22 securing the centralizer anchor 43 in place. The values of angles B and C may be selectable to produce a desired clamping force. It is within the capabilities of those skilled in the art to determine angle values to produce a particular clamping force.
Example 1
[0014] In one actual example of use, the stop collar assembly 20 has been measured to provide a multiple of seven to ten times the gripping force of traditional known stop rings under static loads and up to twenty times the kinetic gripping force. FIG. 4 includes plots of actual applied axial pounds force (ordinate) onto a stop ring over time (abscissa). The plots represent test data for: (1) a prior art existing ring; (2) a stop ring as described herein with angles B and C equal to about 20°; and (3) a stop ring as described herein with angles B and C equal to about 12°. The rings 22 , 24 , 28 were coupled to a test mandrel and an increasing axial load was applied. Where a local maximum occurs for the applied load indicates the particular ring was moved from its mounting by the applied load. The test results indicated that the existing ring supported an axial load up to about 1200 lbs before releasing. The stop ring beveled at 20° withstood loads in excess of 10,000 lbs and the stop ring beveled at 12° remained stable up to the test device maximum applied load of 15,000 lbs. Accordingly, stop rings beveled at more acute angles can withstand higher applied axial loads.
[0015] Alternative values for the angles B and C include angles up to or greater than about 7°, up to or greater than about 8°, up to or greater than about 9°, up to or greater than about 10°, up to or greater than about 11°, up to or greater than about 12°, up to or greater than about 13°, up to or greater than about 14°, up to or greater than about 15°, up to or greater than 16°, up to or greater than about 17°, up to or greater than about 18°, up to or greater than about 19°, up to or greater than about 20°, up to or greater than about 21°, and up to or greater than about 22°. Additionally, the present disclosure includes stop collar assembly 20 embodiments that are not self locking. That is, the angles B and C are such that when applied axial loads are removed from the stop collar assembly 20 , the rings 22 , 24 , 28 have not become press fit together, but instead can be readily separated. Angles B and C that form a “self locking” configuration depend on the ring 22 , 24 , 28 material and application.
[0016] The centralizer 40 is but one example of a piece of auxiliary equipment on a downhole tool 36 that may be secured with the stop collar assembly 20 as disclosed herein. The stop collar assembly 20 is also useful for any other auxiliary device slideable under an axial load that may be attached to or used with a downhole tool. Other examples include a standoff type centralizer, a de-centralizer, an excluder, or a wedge coaxially disposed on the outer surface of a downhole tool for mating with slips that slide along a tool body.
[0017] Optionally, the downhole tool may employ more than one stop collar assembly 20 and may be on opposite ends of the devices such as the centralizer 40 . Other embodiments include a single wedge ring combined with a single annular ring. In such embodiment, the wedge ring may have an anchoring means to hinder axial movement, such as a set screw thereby negating the need for the second annular ring.
[0018] The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. For example, the wedge ring 28 could be integrally included within the remaining portions of the assembly 20 and not as a separate member. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims.
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A stop collar assembly used for axially securing and/or to resist axial sliding of a downhole tool device. The assembly provided on a housing of the downhole tool and includes a generally annular ring having an inner circumference beveled outward proximate to the ring edge. A clamp ring having a raised portion on its outer surface is disposed adjacent and substantially coaxial with the annular ring. Pushing the annular ring against the clamp ring compresses the clamp ring onto the housing to resist axial sliding of the annular ring.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This invention relates to a flip chip package. More particularly, the present invention is related to a flip chip package with solder bars formed therein.
[0003] 2. Related Art
[0004] A well-known semiconductor package, such as a flip chip package is applicable to communication products, portable electronics products, and packages for high-frequency chips. Referring to FIG. 1 , it discloses a conventional and well-know flip chip package 10 , which mainly comprises a chip 20 attached to a substrate 30 in a flip-chip bonding type. The chip 20 has an active surface 22 and a plurality of bonding pads 24 formed thereon. Besides, a plurality of bumps 26 electrically and mechanically connected to the contacts 32 of the substrate 30 . The bumps 26 are formed by conventional bumping process and C4 technology (Controlled Collapse Chip Connection). Furthermore, an underfill 28 is disposed between the chip 20 and the substrate 30 and encapsulates the bumps 26 . In this arrangement, the bonding pads 24 are utilized for signal transmitting, grounded to the substrate and to be noted that the bonding pads 24 are connected to the bumps 26 separately and substantially have the same size with each other.
[0005] As mentioned above, the voltage regulator is provided as a DC to DC converter so as to provide the electronics system with a stable power supply. In apparatus with low power, such as notebooks, mobile phones, usually there is needed an efficient switch converter to manage power supply. However, a well-know and conventional switch converter is manufacture by the packages of small outline IC, small outline package and such packages usually have larger parasitic inductance and parasitic resistance. In addition, such packages can not dissipate the heat, arisen out of electronics systems with high power and high frequency devices formed therein, to external devices or the outside more quickly.
[0006] Although the U.S. Pat. No. 6,229,220 and the TW. Pat 517370 disclose the method of keeping the bump height and the distance between the substrate and the chip from being collapsed by utilizing bumps with two different solder materials formed therein. However, such package still not provides a package with a better thermal and electrical performance.
[0007] Therefore, providing another flip chip package to solve the mentioned-above disadvantages is the most important task in this invention.
SUMMARY OF THE INVENTION
[0008] In view of the above-mentioned problems, this invention is to provide a flip chip package having an electrically conductive bar formed therein for enhancing the thermal and electrical performance.
[0009] To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention specifically provides a flip chip package applicable to such high thermal and electrical performance. Therein, the flip chip package mainly comprises a chip, which has an active surface, a plurality of bonding pads, a passivation layer formed on the active surface and leaves the bonding pads exposed, a plurality of first under bump metallurgy layers, a second under bump metallurgy layer, a plurality of first bumps formed on the first under bump metallurgy layers and a second bump formed on the second under bump metallurgy layer. To be noted that the second under bump metallurgy layer is disposed on at least two of the bonding pads and a portion of the passivation layer between said two bonding pads and each said first under bump metallurgy layer is disposed on one of the corresponding bonding pads respectively. Namely, the second under bump metallurgy layer is extended from one bonding to another boning pad and located over the passivation layer located between the two bonding pads. In other words, the area of said each first under bump metallurgy layer is smaller than that of the second under bump metallurgy layer from a top view. Moreover, the second bump disposed on the second under bump metallurgy layer may form a bar, a ring, a rectangle and an ellipse. When the material of the second bump is made of solder, it becomes a solder bar.
[0010] As mentioned above, the second under bump metallurgy layer has a large area and the second bump has a large size so that the second bump can be taken as ground bump to ground to a substrate. Hence, the electrical and thermal performance will increase and enhance.
[0011] It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention will become more fully understood from the detailed description given herein below illustrations only, and thus are not limitative of the present invention, and wherein:
[0013] FIG. 1 is a cross-sectional view of a conventional flip chip package;
[0014] FIG. 2 is a top view of a flip chip package according to the preferred embodiment of the present invention;
[0015] FIG. 3 is a cross-sectional view of a flip chip package of FIG. 2 ;
[0016] FIG. 4 is a bottom view of a flip chip package of FIG. 2 ;
[0017] FIG. 5 a and FIG. 5 b are cross-sectional views of solder bump and solder bar provided in the flip chip package of FIG. 2 ; and
[0018] FIGS. 6 to 11 are partially enlarged cross-sectional views showing the progression of steps for forming the flip chip package according to the preferred embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The flip chip package according to the preferred embodiments of this invention will be described herein below with reference to the accompanying drawings, wherein the same reference numbers are used in the drawings and the description to refer to the same or like parts.
[0020] As shown in FIGS. 2, 3 and 4 , which illustrate a preferred embodiment of this invention. The flip chip package 100 mainly comprises a chip 120 flip-chip bonded to a substrate 130 . Said chip 120 has an active surface 122 and a plurality of bonding pads 124 formed on the active surface 122 . A plurality of bumps, including the solder bump 160 and the solder bar 162 as shown in FIGS. 3 and 4 , are disposed over the bonding pads 124 . A plurality of under bump metallurgy layers 150 and 152 formed between the bumps and the chip 120 . To be more clearly, the under bump metallurgy layer 150 is substantially shaped into a circle and connected to the solder bump 160 . In addition, the under bump metallurgy layer 152 covers at least two bonding pads 124 by extending one of the two bonding pads 124 to the other of the two bonding pads 124 . Usually, there is a passivation layer 132 , as shown in FIG. 5 a , formed over the active surface 122 and leaves the bonding pads 124 exposed. Accordingly, as mentioned above and the under bump metallurgy layer 152 may extend along the passivation layer 123 between the two bonding pads 124 as shown in FIG. 5 a . On the basis, the bumps, such as the solder bar 162 is disposed over the two boning pads 124 and a portion of the passivation layer 132 between the two bonding pads 124 .
[0021] As mentioned above, the chip 120 are electrically and mechanically connected to the substrate 130 through the under bump metallurgy layers 150 and 152 , and the bumps 160 and 162 . Moreover, in order to release the stress at the bumps 160 and 162 , there is further provided an underfill 128 disposed between the chip 120 and the substrate 130 for being utilized for releasing the stress to prevent the bumps 160 and 162 from being damaged.
[0022] To be noted that the bonding pads 124 of the chip 120 can be transmitted the signals from the chip 120 , and grounded to the substrate 130 through the solder bar 162 so as to enhance the electrical and thermal performance. Because the under bump metallurgy layer 152 covering at least two bonding pads 124 , the area of the under bump metallurgy layer 152 is usually grounded to the substrate 130 or regarded as a power terminal for enhancing the electrical and thermal performance of the package. To be noted, as shown in FIG. 4 , the solder bar 162 may be shaped into a rectangle with a curved edge, an ellipse, a ring and the solder bump 160 may be shaped into a circle. Namely, the first under bump metallurgy layer may be shaped into a circle; and the second under bump metallurgy layer may be shaped into a rectangle with a curved edge, an ellipse, a ring.
[0023] Next, referring to FIG. 5 a again, it illustrates a chip 120 not attached to the substrate 130 . Usually, when the bumps are solder bumps 160 and a solder bar 162 , the bumps are eutectic bumps with a ratio of lead to tin being 37 to 63. When the bumps 160 and 162 are high-lead bumps, the ratio of the bumps 160 and 162 of tin to lead is 5 and 95. In addition, the bumps 160 and 162 usually comprise anther metals formed therein, such as In.
[0024] Moreover, referring to FIG. 5 b , it illustrates another embodiment showing the chip 120 is not attached to the substrate 130 . Specifically, the difference of this embodiment from that as shown above, the solder bumps 160 and the solder bar 162 both has a first solder material and a second solder material, with a high melting point than that of the first solder material, formed on the first solder material respectively so as to keep the solder bumps 160 and the solder bar 162 from being collapsed after the solder bumps 160 and the solder bar 162 are reflowed. Optionally, the melting point of the first solder material is higher than the second solder material at about 20° C. For example, the first solder material 146 has a solder composition with a ratio of tin to lead being 5 to 95 and the second solder material has a solder composition with a ratio of tin to lead being 63 to 37. Therein, the melting point of the second solder material is ranged between 200 and 250° C.; and the melting point of the first solder material is ranged between 320 and 360° C. On the basis, when the bumps are reflowed, the second solder material is reflowed to encapsulate the first solder material and have the first solder material secured to the second solder material.
[0025] Moreover, the contacts on the substrate may have the same shape with that of the corresponding under bump metallurgy layers so as to have the bumps secured to the substrate well. In addition, the solder bar 162 has a larger size and area than that of the solder bump 160 so that the electrical performance and the thermal performance of the package 100 can be enhanced.
[0026] Next, referring to FIGS. 6 to 12 , which illustrate the manufacture processes of the flip chip package as shown above. Again, referring to FIG. 6 , the chip 120 has an active surface 122 and a plurality of bonding pads 124 formed thereon. Therein, a passivation layer 123 is disposed on the active surface 122 and leaves the bonding pads 124 exposed. Then, a metal layer 142 , usually called an under bump metallurgy layer, is formed over the active surface and the passivation layer. Therein, the metal layer 142 has three layers formed therein. An adhesion layer, an oxidation barrier and a wetting layer are formed from the side close to the active surface 122 to the other side far away from the active surface 122 .
[0027] Next, referring to FIG. 7 , a photo-resist layer 144 is formed and then a plurality of openings 170 and 172 formed in the photoresist layer 144 by lithography and development. Afterwards, as shown in FIG. 8 , a first solder material is disposed in the openings 170 and 172 . Next, a second solder material 148 with a melting point lower than that of the first solder material 146 is disposed on the first solder material 146 . Therein, the first solder material 146 and the second solder material 148 can be formed by electroplating or screen-printing methods.
[0028] Then, optionally, a reflow process is performed to have the first solder material 146 securely attached to the second solder material 148 and the first solder material 146 is secured to the chip 120 , when the first solder material 146 and the second solder material 148 is formed by screen-printing.
[0029] Next, as shown in FIG. 10 , the photo-resist layer 144 is then removed. Then, an etching process is performed to pattern the under bump metallurgy. Therein, the portion of the under bump metallurgy layer is not covered by the first solder material is removed. To be noted, if a reflow process is not performed to have the first solder material 146 and the second solder material 148 secured to each other, such reflow process can be performed after the patterned under bump metallurgy layer is formed.
[0030] As mentioned above, if only one solder material is formed in the openings 170 and 172 , the photo-resist layer 144 can be removed in sequence of the step of forming solder material in the openings 170 and 172 .
[0031] Although the invention has been described in considerable detail with reference to certain preferred embodiments, it will be appreciated and understood that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the appended claims.
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A semiconductor chip with bumps formed therein comprises an active surface, a plurality of bonding pads, a passivation layer, a plurality of first UBMs (under bump metallurgy), a second UBM, a plurality of first bumps, and a plurality of second bumps. The bonding pads are disposed on the active surface of the semiconductor chip. The passivation layer covers the active surface of the semiconductor chip with the pads exposed out of the passivation layer. The first UMBs are individually disposed on the bonding pads. The second UMB is disposed on at least two of the bonding pads. The first bumps are disposed on the first UMBs. The second bumps are disposed on the second UBM.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application for U.S. patent is a continuation of U.S. patent application Ser. No. 12/201,554 filed Aug. 29, 2008, which is a division of U.S. patent application Ser. No. 10/818,073 filed Apr. 5, 2004, now U.S. Pat. No. 7,571,511, which is a continuation of U.S. patent application Ser. No. 10/320,729 filed Dec. 16, 2002, now U.S. Pat. No. 6,883,201, which claims the benefit of U.S. Provisional Application No. 60/345,764 filed on Jan. 3, 2002, the contents of all of which are expressly incorporated by reference herein in their entireties. The subject matter of this application is also related to commonly-owned U.S. patent application Ser. No. 09/768,773 filed Jan. 24, 2001, now U.S. Pat. No. 6,594,844, U.S. patent application Ser. No. 10/167,851 filed Jun. 12, 2002, now U.S. Pat. No. 6,809,490, and U.S. patent application Ser. No. 10/056,804 filed Jan. 24, 2002, U.S. Pat. No. 6,690,134, which are all expressly incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The present invention relates to cleaning devices, and more particularly, to an autonomous floor-cleaning robot that comprises a self-adjustable cleaning head subsystem that includes a dual-stage brush assembly having counter-rotating, asymmetric brushes and an adjacent, but independent, vacuum assembly such that the cleaning capability and efficiency of the self-adjustable cleaning head subsystem is optimized while concomitantly minimizing the power requirements thereof. The autonomous floor-cleaning robot further includes a side brush assembly for directing particulates outside the envelope of the robot into the self-adjustable cleaning head subsystem.
[0004] (2) Description of Related Art
[0005] Autonomous robot cleaning devices are known in the art. For example, U.S. Pat. Nos. 5,940,927 and 5,781,960 disclose an Autonomous Surface Cleaning Apparatus and a Nozzle Arrangement for a Self-Guiding Vacuum Cleaner. One of the primary requirements for an autonomous cleaning device is a self-contained power supply—the utility of an autonomous cleaning device would be severely degraded, if not outright eliminated, if such an autonomous cleaning device utilized a power cord to tap into an external power source.
[0006] And, while there have been distinct improvements in the energizing capabilities of self-contained power supplies such as batteries, today's self-contained power supplies are still time-limited in providing power. Cleaning mechanisms for cleaning devices such as brush assemblies and vacuum assemblies typically require large power loads to provide effective cleaning capability. This is particularly true where brush assemblies and vacuum assemblies are configured as combinations, since the brush assembly and/or the vacuum assembly of such combinations typically have not been designed or configured for synergic operation.
[0007] A need exists to provide an autonomous cleaning device that has been designed and configured to optimize the cleaning capability and efficiency of its cleaning mechanisms for synergic operation while concomitantly minimizing or reducing the power requirements of such cleaning mechanisms.
SUMMARY OF THE INVENTION
[0008] One object of the present invention is to provide a cleaning device that is operable without human intervention to clean designated areas.
[0009] Another object of the present invention is to provide such an autonomous cleaning device that is designed and configured to optimize the cleaning capability and efficiency of its cleaning mechanisms for synergic operations while concomitantly minimizing the power requirements of such mechanisms.
[0010] These and other objects of the present invention are provided by one embodiment autonomous floor-cleaning robot according to the present invention that comprises a housing infrastructure including a chassis, a power subsystem; for providing the energy to power the autonomous floor-cleaning robot, a motive subsystem operative to propel the autonomous floor-cleaning robot for cleaning operations, a control module operative to control the autonomous floor-cleaning robot to effect cleaning operations, and a self-adjusting cleaning head subsystem that includes a deck mounted in pivotal combination with the chassis, a brush assembly mounted in combination with the deck and powered by the motive subsystem to sweep up particulates during cleaning operations, a vacuum assembly disposed in combination with the deck and powered by the motive subsystem to ingest particulates during cleaning operations, and a deck height adjusting subassembly mounted in combination with the motive subsystem for the brush assembly, the deck, and the chassis that is automatically operative in response to a change in torque in said brush assembly to pivot the deck with respect to said chassis and thereby adjust the height of the brushes from the floor. The autonomous floor-cleaning robot also includes a side brush assembly mounted in combination with the chassis and powered by the motive subsystem to entrain particulates outside the periphery of the housing infrastructure and to direct such particulates towards the self-adjusting cleaning head subsystem.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A more complete understanding of the present invention and the attendant features and advantages thereof may be had by reference to the following detailed description of the invention when considered in conjunction with the accompanying drawings wherein:
[0012] FIG. 1 is a schematic representation of an autonomous floor-cleaning robot according to the present invention.
[0013] FIG. 2 is a perspective view of one embodiment of an autonomous floor-cleaning robot according to the present invention.
[0014] FIG. 2A is a bottom plan view of the autonomous floor-cleaning robot of FIG. 2 .
[0015] FIG. 3A is a top, partially-sectioned plan view, with cover removed, of another embodiment of an autonomous floor-cleaning robot according to the present invention.
[0016] FIG. 3B is a bottom, partially-section plan view of the autonomous floor-cleaning robot embodiment of FIG. 3A .
[0017] FIG. 3C is a side, partially sectioned plan view of the autonomous floor-cleaning robot embodiment of FIG. 3A .
[0018] FIG. 4A is a top plan view of the deck and chassis of the autonomous floor-cleaning robot embodiment of FIG. 3A .
[0019] FIG. 4B is a cross-sectional view of FIG. 4A taken along line B-B thereof.
[0020] FIG. 4C is a perspective view of the deck-adjusting subassembly of autonomous floor-cleaning robot embodiment of FIG. 3A .
[0021] FIG. 5A is a first exploded perspective view of a dust cartridge for the autonomous floor-cleaning robot embodiment of FIG. 3A .
[0022] FIG. 5B is a second exploded perspective view of the dust cartridge of FIG. 5A .
[0023] FIG. 6 is a perspective view of a dual-stage brush assembly including a flapper brush and a main brush for the autonomous floor-cleaning robot embodiment of FIG. 3A .
[0024] FIG. 7A is a perspective view illustrating the blades and vacuum compartment for the autonomous floor cleaning robot embodiment of FIG. 3A .
[0025] FIG. 7B is a partial perspective exploded view of the autonomous floor-cleaning robot embodiment of FIG. 7A .
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to the drawings where like reference numerals identify corresponding or similar elements throughout the several views, FIG. 1 is a schematic representation of an autonomous floor-cleaning robot 10 according to the present invention. The robot 10 comprises a housing infrastructure 20 , a power subsystem 30 , a motive subsystem 40 , a sensor subsystem 50 , a control module 60 , a side brush assembly 70 , and a self-adjusting cleaning head subsystem 80 . The power subsystem 30 , the motive subsystem 40 , the sensor subsystem 50 , the control module 60 , the side brush assembly 70 , and the self-adjusting cleaning head subsystem 80 are integrated in combination with the housing infrastructure 20 of the robot 10 as described in further detail in the following paragraphs.
[0027] In the following description of the autonomous floor-cleaning robot 10 , use of the terminology “forward/fore” refers to the primary direction of motion of the autonomous floor-cleaning robot 10 , and the terminology fore-aft axis (see reference characters “FA” in FIGS. 3A , 3 B) defines the forward direction of motion (indicated by arrowhead of the fore-aft axis FA), which is coincident with the fore-aft diameter of the robot 10 .
[0028] Referring to FIGS. 2 , 2 A, and 3 A- 3 C, the housing infrastructure 20 of the robot 10 comprises a chassis 21 , a cover 22 , a displaceable bumper 23 , a nose wheel subassembly 24 , and a carrying handle 25 . The chassis 21 is preferably molded from a material such as plastic as a unitary element that includes a plurality of preformed wells, recesses, and structural members for, inter alia, mounting or integrating elements of the power subsystem 30 , the motive subsystem 40 , the sensor subsystem 50 , the side brush assembly 70 , and the self-adjusting cleaning head subsystem 80 in combination with the chassis 21 . The cover 22 is preferably molded from a material such as plastic as a unitary element that is complementary in configuration with the chassis 21 and provides protection of and access to elements/components mounted to the chassis 21 and/or comprising the self-adjusting cleaning head subsystem 80 . The chassis 21 and the cover 22 are detachably integrated in combination by any suitable means, e.g., screws, and in combination, the chassis 21 and cover 22 form a structural envelope of minimal height having a generally cylindrical configuration that is generally symmetrical along the fore-aft axis FA.
[0029] The displaceable bumper 23 , which has a generally arcuate configuration, is mounted in movable combination at the forward portion of the chassis 21 to extend outwardly therefrom, i.e., the normal operating position. The mounting configuration of the displaceable bumper is such that the bumper 23 is displaced towards the chassis 21 (from the normal operating position) whenever the bumper 23 encounters a stationary object or obstacle of predetermined mass, i.e., the displaced position, and returns to the normal operating position when contact with the stationary object or obstacle is terminated (due to operation of the control module 60 which, in response to any such displacement of the bumper 23 , implements a “bounce” mode that causes the robot 10 to evade the stationary object or obstacle and continue its cleaning routine, e.g., initiate a random—or weighted-random—turn to resume forward movement in a different direction). The mounting configuration of the displaceable bumper 23 comprises a pair of rotatable support members 23 RSM, which are operative to facilitate the movement of the bumper 23 with respect to the chassis 21 .
[0030] The pair of rotatable support members 23 RSM are symmetrically mounted about the fore-aft axis FA of the autonomous floor-cleaning robot 10 proximal the center of the displaceable bumper 23 in a V-configuration. One end of each support member 23 RSM is rotatably mounted to the chassis 21 by conventional means, e.g., pins/dowel and sleeve arrangement, and the other end of each support member 23 RSM is likewise rotatably mounted to the displaceable bumper 23 by similar conventional means. A biasing spring (not shown) is disposed in combination with each rotatable support member 23 RSM and is operative to provide the biasing force necessary to return the displaceable bumper 23 (through rotational movement of the support members 23 RSM) to the normal operating position whenever contact with a stationary object or obstacle is terminated.
[0031] The embodiment described herein includes a pair of bumper arms 23 BA that are symmetrically mounted in parallel about the fore-aft diameter FA of the autonomous floor-cleaning robot 10 distal the center of the displaceable bumper 23 . These bumper arms 23 BA do not per se provide structural support for the displaceable bumper 23 , but rather are a part of the sensor subsystem 50 that is operative to determine the location of a stationary object or obstacle encountered via the bumper 23 . One end of each bumper arm 23 BA is rigidly secured to the displaceable bumper 23 and the other end of each bumper arm 23 BA is mounted in combination with the chassis 21 in a manner, e.g., a slot arrangement such that, during an encounter with a stationary object or obstacle, one or both bumper arms 23 BA are linearly displaceable with respect to the chassis 21 to activate an associated sensor, e.g., IR break beam sensor, mechanical switch, capacitive sensor, which provides a corresponding signal to the control module 60 to implement the “bounce” mode. Further details regarding the operation of this aspect of the sensor subsystem 50 , as well as alternative embodiments of sensors having utility in detecting contact with or proximity to stationary objects or obstacles can be found in commonly-owned, co-pending U.S. patent application Ser. No. 10/056,804, filed 24 Jan. 2002, entitled Method and System for Multi-Mode Coverage for an Autonomous Robot.
[0032] The nose-wheel subassembly 24 comprises a wheel 24 W rotatably mounted in combination with a clevis member 24 CM that includes a mounting shaft. The clevis mounting shaft 24 CM is disposed in a well in the chassis 21 at the forward end thereof on the fore-aft diameter of the autonomous floor-cleaning robot 10 . A biasing spring 24 BS (hidden behind a leg of the clevis member 24 CM in FIG. 3C ) is disposed in combination with the clevis mounting shaft 24 CM and operative to bias the nose-wheel subassembly 24 to an ‘extended’ position whenever the nose-wheel subassembly 24 loses contact with the surface to be cleaned. During cleaning operations, the weight of the autonomous floor-cleaning robot 10 is sufficient to overcome the force exerted by the biasing spring 24 BS to bias the nose-wheel subassembly 24 to a partially retracted or operating position wherein the wheel rotates freely over the surface to be cleaned. Opposed triangular or conical wings 24 TW extend outwardly from the ends of the clevis member to prevent the side of the wheel from catching on low obstacle during turning movements of the autonomous floor-cleaning robot 10 . The wings 24 TW act as ramps in sliding over bumps as the robot turns.
[0033] Ends 25 E of the carrying handle 25 are secured in pivotal combination with the cover 22 at the forward end thereof, centered about the fore-aft axis FA of the autonomous floor-cleaning robot 10 . With the autonomous floor-cleaning robot 10 resting on or moving over a surface to be cleaned, the carrying handle 25 lies approximately flush with the surface of the cover 22 (the weight of the carrying handle 25 , in conjunction with arrangement of the handle-cover pivot configuration, is sufficient to automatically return the carrying handle 25 to this flush position due to gravitational effects). When the autonomous floor-cleaning robot 10 is picked up by means of the carrying handle 25 , the aft end of the autonomous floor-cleaning robot 10 lies below the forward end of the autonomous floor-cleaning robot 10 so that particulate debris is not dislodged from the self-adjusting cleaning head subsystem 80 .
[0034] The power subsystem 30 of the described embodiment provides the energy to power individual elements/components of the motive subsystem 40 , the sensor subsystem 50 , the side brush assembly 70 , and the self-adjusting cleaning head subsystem 80 and the circuits and components of the control module 60 via associated circuitry 32 - 4 , 32 - 5 , 32 - 7 , 32 - 8 , and 32 - 6 , respectively (see FIG. 1 ) during cleaning operations. The power subsystem 30 for the described embodiment of the autonomous floor-cleaning robot 10 comprises a rechargeable battery pack 34 such as a NiMH battery pack. The rechargeable battery pack 34 is mounted in a well formed in the chassis 21 (sized specifically for mounting/retention of the battery pack 34 ) and retained therein by any conventional means, e.g., spring latches (not shown). The battery well is covered by a lid 34 L secured to the chassis 21 by conventional means such as screws. Affixed to the lid 34 L are friction pads 36 that facilitate stopping of the autonomous floor-cleaning robot 10 during automatic shutdown. The friction pads 36 aid in stopping the robot upon the robot's attempting to drive over a cliff. The rechargeable battery pack 34 is configured to provide sufficient power to run the autonomous floor-cleaning robot 10 for a period of sixty (60) to ninety (90) minutes on a full charge while meeting the power requirements of the elements/components comprising motive subsystem 40 , the sensor subsystem 50 , the side brush assembly 70 , the self-adjusting cleaning head subsystem 80 , and the circuits and components of the control module 60 .
[0035] The motive subsystem 40 comprises the independent means that: (1) propel the autonomous floor-cleaning robot 10 for cleaning operations; (2) operate the side brush assembly 70 ; and (3) operate the self-adjusting cleaning head subsystem 80 during such cleaning operations. Such independent means includes right and left main wheel subassemblies 42 A, 42 B, each subassembly 42 A, 42 B having its own independently-operated motor 42 A M , 42 B M , respectively, an independent electric motor 44 for the side brush assembly 70 , and two independent electric motors 46 , 48 for the self-adjusting brush subsystem 80 , one motor 46 for the vacuum assembly and one motor 48 for the dual-stage brush assembly.
[0036] The right and left main wheel subassemblies 42 A, 42 B are independently mounted in wells of the chassis 21 formed at opposed ends of the transverse diameter of the chassis 21 (the transverse diameter is perpendicular to the fore-aft axis FA of the robot 10 ). Mounting at this location provides the autonomous floor-cleaning robot 10 with an enhanced turning capability, since the main wheel subassemblies 42 A, 42 B motor can be independently operated to effect a wide range of turning maneuvers, e.g., sharp turns, gradual turns, turns in place.
[0037] Each main wheel subassembly 42 A, 42 B comprises a wheel 42 A W , 42 B W rotatably mounted in combination with a clevis member 42 A CM , 42 B CM . Each clevis member 42 A CM , 42 B CM is pivotally mounted to the chassis 21 aft of the wheel axis of rotation (see FIG. 3C which illustrates the wheel axis of rotation 42 A AR ; the wheel axis of rotation for wheel subassembly 42 B, which is not shown, is identical), i.e., independently suspended. The aft pivot axis 42 A PA , 42 B PA (see FIG. 3A ) of the main wheel subassemblies 42 A, 42 B facilitates the mobility of the autonomous floor-cleaning robot 10 , i.e., pivotal movement of the subassemblies 42 A, 42 B through a predetermined arc. The motor 42 A M , 42 B M associated with each main wheel subassembly 42 A, 42 B is mounted to the aft end of the clevis member 42 A CM , 42 B CM . One end of a tension spring 42 B TS (the tension spring for the right wheel subassembly 42 A is not illustrated, but is identical to the tension spring 42 BTS of the left wheel subassembly 42 A) is attached to the aft portion of the clevis member 42 B CM and the other end of the tension spring 42 B TS is attached to the chassis 21 forward of the respective wheel 42 A W , 42 B W .
[0038] Each tension spring is operative to rotatably bias the respective main wheel subassembly 42 A, 42 B (via pivotal movement of the corresponding clevis member 42 A CM , 42 B CM through the predetermined arc) to an ‘extended’ position when the autonomous floor-cleaning robot 10 is removed from the floor (in this ‘extended’ position the wheel axis of rotation lies below the bottom plane of the chassis 21 ). With the autonomous floor-cleaning robot 10 resting on or moving over a surface to be cleaned, the weight of autonomous floor-cleaning robot 10 gravitationally biases each main wheel subassembly 42 A, 42 B into a retracted or operating position wherein axis of rotation of the wheels are approximately coplanar with bottom plane of the chassis 21 . The motors 42 A M , 42 B M of the main wheel subassemblies 42 A, 42 B are operative to drive the main wheels: (1) at the same speed in the same direction of rotation to propel the autonomous floor-cleaning robot 10 in a straight line, either forward or aft; (2) at different speeds (including the situation wherein one wheel is operated at zero speed) to effect turning patterns for the autonomous floor-cleaning robot 10 ; or (3) at the same speed in opposite directions of rotation to cause the robot 10 to turn in place, i.e., “spin on a dime”.
[0039] The wheels 42 A W , 42 B W of the main wheel subassemblies 42 A, 42 B preferably have a “knobby” tread configuration 42 A KT , 42 B KT . This knobby tread configuration 42 A KT , 42 B KT provides the autonomous floor-cleaning robot 10 with enhanced traction, particularly when traversing smooth surfaces and traversing between contiguous surfaces of different textures, e.g., bare floor to carpet or vice versa. This knobby tread configuration 42 A KT , 42 B KT also prevents tufted fabric of carpets/rags from being entrapped in the wheels 42 A W , 42 B and entrained between the wheels and the chassis 21 during movement of the autonomous floor-cleaning robot 10 . One skilled in the art will appreciate, however, that other tread patterns/configurations are within the scope of the present invention.
[0040] The sensor subsystem 50 comprises a variety of different sensing units that may be broadly characterized as either: (1) control sensing units 52 ; or (2) emergency sensing units 54 . As the names imply, control sensing units 52 are operative to regulate the normal operation of the autonomous floor-cleaning robot 10 and emergency sensing units 54 are operative to detect situations that could adversely affect the operation of the autonomous floor-cleaning robot 10 (e.g., stairs descending from the surface being cleaned) and provide signals in response to such detections so that the autonomous floor-cleaning robot 10 can implement an appropriate response via the control module 60 . The control sensing units 52 and emergency sensing units 54 of the autonomous floor-cleaning robot 10 are summarily described in the following paragraphs; a more complete description can be found in commonly-owned, co-pending U.S. patent application Ser. Nos. 09/768,773, filed 24 Jan. 2001, entitled Robot Obstacle Detection System, 10/167,851, 12 Jun. 2002, entitled Method and System for Robot Localization and Confinement, and 10/056,804, filed 24 Jan. 2002, entitled Method and System for Multi-Mode Coverage for an Autonomous Robot.
[0041] The control sensing units 52 include obstacle detection sensors 52 OD mounted in conjunction with the linearly-displaceable bumper arms 23 BA of the displaceable bumper 23 , a wall-sensing assembly 52 WS mounted in the right-hand portion of the displaceable bumper 23 , a virtual wall sensing assembly 52 VWS mounted atop the displaceable bumper 23 along the fore-aft diameter of the autonomous floor-cleaning robot 10 , and an IR sensor/encoder combination 52 WE mounted in combination with each wheel subassembly 42 A, 42 B.
[0042] Each obstacle detection sensor 52 OD includes an emitter and detector combination positioned in conjunction with one of the linearly displaceable bumper arms 23 BA so that the sensor 52 OD is operative in response to a displacement of the bumper arm 23 BA to transmit a detection signal to the control module 60 . The wall sensing assembly 52 WS includes an emitter and detector combination that is operative to detect the proximity of a wall or other similar structure and transmit a detection signal to the control module 60 . Each IR sensor/encoder combination 52 WE is operative to measure the rotation of the associated wheel subassembly 42 A, 42 B and transmit a signal corresponding thereto to the control module 60 .
[0043] The virtual wall sensing assembly 52 VWS includes detectors that are operative to detect a force field and a collimated beam emitted by a stand-alone emitter (the virtual wall unit—not illustrated) and transmit respective signals to the control module 60 . The autonomous floor cleaning robot 10 is programmed not to pass through the collimated beam so that the virtual wall unit can be used to prevent the robot 10 from entering prohibited areas, e.g., access to a descending staircase, room not to be cleaned. The robot 10 is further programmed to avoid the force field emitted by the virtual wall unit, thereby preventing the robot 10 from overrunning the virtual wall unit during floor cleaning operations.
[0044] The emergency sensing units 54 include ‘cliff detector’ assemblies 54 CD mounted in the displaceable bumper 23 , wheeldrop assemblies 54 WD mounted in conjunction with the left and right main wheel subassemblies 42 A, 42 B and the nose-wheel assembly 24 , and current stall sensing units 54 CS for the motor 42 A M , 42 B M of each main wheel subassembly 42 A, 42 B and one for the motors 44 , 48 (these two motors are powered via a common circuit in the described embodiment). For the described embodiment of the autonomous floor-cleaning robot 10 , four (4) cliff detector assemblies 54 CD are mounted in the displaceable bumper 23 . Each cliff detector assembly 54 CD includes an emitter and detector combination that is operative to detect a predetermined drop in the path of the robot 10 , e.g., descending stairs, and transmit a signal to the control module 60 . The wheeldrop assemblies 54 WD are operative to detect when the corresponding left and right main wheel subassemblies 32 A, 32 B and/or the nose-wheel assembly 24 enter the extended position, e.g., a contact switch, and to transmit a corresponding signal to the control module 60 . The current stall sensing units 54 CS are operative to detect a change in the current in the respective motor, which indicates a stalled condition of the motor's corresponding components, and transmit a corresponding signal to the control module 60 .
[0045] The control module 60 comprises the control circuitry (see, e.g., control lines 60 - 4 , 60 - 5 , 60 - 7 , and 60 - 8 in FIG. 1 ) and microcontroller for the autonomous floor-cleaning robot 10 that controls the movement of the robot 10 during floor cleaning operations and in response to signals generated by the sensor subsystem 50 . The control module 60 of the autonomous floor-cleaning robot 10 according to the present invention is preprogrammed (hardwired, software, firmware, or combinations thereof) to implement three basic operational modes, i.e., movement patterns, that can be categorized as: (1) a “spot-coverage” mode; (2) a “wall/obstacle following” mode; and (3) a “bounce” mode. In addition, the control module 60 is preprogrammed to initiate actions based upon signals received from sensor subsystem 50 , where such actions include, but are not limited to, implementing movement patterns (2) and (3), an emergency stop of the robot 10 , or issuing an audible alert. Further details regarding the operation of the robot 10 via the control module 60 are described in detail in commonly-owned, co-pending U.S. patent application Ser. Nos. 09/768,773, filed 24 Jan. 2001, entitled Robot Obstacle Detection System, 10/167,851, filed 12 Jun. 2002, entitled Method and System for Robot Localization and Confinement, and 10/056,804, filed 24 Jan. 2002, entitled Method and System for Multi-Mode Coverage for an Autonomous Robot.
[0046] The side brush assembly 70 is operative to entrain macroscopic and microscopic particulates outside the periphery of the housing infrastructure 20 of the autonomous floor-cleaning robot 10 and to direct such particulates towards the self-adjusting cleaning head subsystem 80 . This provides the robot 10 with the capability of cleaning surfaces adjacent to baseboards (during the wall-following mode).
[0047] The side brush assembly 70 is mounted in a recess formed in the lower surface of the right forward quadrant of the chassis 21 (forward of the right main wheel subassembly 42 A just behind the right hand end of the displaceable bumper 23 ). The side brush assembly 70 comprises a shaft 72 having one end rotatably connected to the electric motor 44 for torque transfer, a hub 74 connected to the other end of the shaft 72 , a cover plate 75 surrounding the hub 74 , a brush means 76 affixed to the hub 74 , and a set of bristles 78 .
[0048] The cover plate 75 is configured and secured to the chassis 21 to encompass the hub 74 in a manner that prevents the brush means 76 from becoming stuck under the chassis 21 during floor cleaning operations.
[0049] For the embodiment of FIGS. 3A-3C , the brush means 76 comprises opposed brush arms that extend outwardly from the hub 74 . These brush arms 76 are formed from a compliant plastic or rubber material in an “L”/hockey stick configuration of constant width. The configuration and composition of the brush arms 76 , in combination, allows the brush arms 76 to resiliently deform if an obstacle or obstruction is temporarily encountered during cleaning operations. Concomitantly, the use of opposed brush arms 76 of constant width is a trade-off (versus using a full or partial circular brush configuration) that ensures that the operation of the brush means 76 of the side brush assembly 70 does not adversely impact (i.e., by occlusion) the operation of the adjacent cliff detector subassembly 54 CD (the left-most cliff detector subassembly 54 CD in FIG. 3B ) in the displaceable bumper 23 . The brush arms 76 have sufficient length to extend beyond the outer periphery of the autonomous floor-cleaning robot 10 , in particular the displaceable bumper 23 thereof. Such a length allows the autonomous floor-cleaning robot 10 to clean surfaces adjacent to baseboards (during the wall-following mode) without scrapping of the wall/baseboard by the chassis 21 and/or displaceable bumper 23 of the robot 10 .
[0050] The set of bristles 78 is set in the outermost free end of each brush arm 76 (similar to a toothbrush configuration) to provide the sweeping capability of the side brush assembly 70 . The bristles 78 have a length sufficient to engage the surface being cleaned with the main wheel subassemblies 42 A, 42 B and the nose-wheel subassembly 24 in the operating position.
[0051] The self-adjusting cleaning head subsystem 80 provides the cleaning mechanisms for the autonomous floor-cleaning robot 10 according to the present invention. The cleaning mechanisms for the preferred embodiment of the self-adjusting cleaning head subsystem 80 include a brush assembly 90 and a vacuum assembly 100 .
[0052] For the described embodiment of FIGS. 3A-3C , the brush assembly 90 is a dual-stage brush mechanism, and this dual-stage brush assembly 90 and the vacuum assembly 100 are independent cleaning mechanisms, both structurally and functionally, that have been adapted and designed for use in the robot 10 to minimize the over-all power requirements of the robot 10 while simultaneously providing an effective cleaning capability. In addition to the cleaning mechanisms described in the preceding paragraph, the self-adjusting cleaning subsystem 80 includes a deck structure 82 pivotally coupled to the chassis 21 , an automatic deck adjusting subassembly 84 , a removable dust cartridge 86 , and one or more bails 88 shielding the dual-stage brush assembly 90 .
[0053] The deck 82 is preferably fabricated as a unitary structure from a material such as plastic and includes opposed, spaced-apart sidewalls 82 SW formed at the aft end of the deck 82 (one of the sidewalls 82 SW comprising a U-shaped structure that houses the motor 46 , a brush-assembly well 82 W, a lateral aperture 82 LA formed in the intermediate portion of the lower deck surface, which defines the opening between the dual-stage brush assembly 90 and the removable dust cartridge 86 , and mounting brackets 82 MB formed in the forward portion of the upper deck surface for the motor 48 .
[0054] The sidewalls 82 SW are positioned and configured for mounting the deck 82 in pivotal combination with the chassis 21 by a conventional means, e.g., a revolute joint (see reference characters 82 RJ in FIG. 3A ). The pivotal axis of the deck 82 -chassis 21 combination is perpendicular to the fore-aft axis FA of the autonomous floor-cleaning robot 10 at the aft end of the robot 10 (see reference character 82 PA which identifies the pivotal axis in FIG. 3A ).
[0055] The mounting brackets 82 MB are positioned and configured for mounting the constant-torque motor 48 at the forward lip of the deck 82 . The rotational axis of the mounted motor 48 is perpendicular to the fore-aft diameter of the autonomous floor-cleaning robot 10 (see reference character 48 RA which identifies the rotational axis of the motor 48 in FIG. 3A ). Extending from the mounted motor 48 is an shaft 48 S for transferring the constant torque to the input side of a stationary, conventional dual-output gearbox 48 B (the housing of the dual-output gearbox 48 B is fabricated as part of the deck 82 ).
[0056] The desk adjusting subassembly 84 , which is illustrated in further detail in FIGS. 4A-4C , is mounted in combination with the motor 48 , the deck 82 and the chassis 21 and operative, in combination with the electric motor 48 , to provide the physical mechanism and motive force, respectively, to pivot the deck 82 with respect to the chassis 21 about pivotal axis 82 PA whenever the dual-stage brush assembly 90 encounters a situation that results in a predetermined reduction in the rotational speed of the dual-stage brush assembly 90 . This situation, which most commonly occurs as the autonomous floor-cleaning robot 10 transitions between a smooth surface such as a floor and a carpeted surface, is characterized as the ‘adjustment mode’ in the remainder of this description.
[0057] The deck adjusting subassembly 84 for the described embodiment of FIG. 3A includes a motor cage 84 MC, a pulley 84 P, a pulley cord 84 C, an anchor member 84 AM, and complementary cage stops 84 CS. The motor 48 is non-rotatably secured within the motor cage 84 MC and the motor cage 84 MC is mounted in rotatable combination between the mounting brackets 82 MB. The pulley 84 P is fixedly secured to the motor cage 84 MC on the opposite side of the interior mounting bracket 82 MB in such a manner that the shaft 48 S of the motor 48 passes freely through the center of the pulley 84 P. The anchor member 84 AM is fixedly secured to the top surface of the chassis 21 in alignment with the pulley 84 P.
[0058] One end of the pulley cord 84 C is secured to the anchor member 84 AM and the other end is secured to the pulley 84 P in such a manner, that with the deck 82 in the ‘down’ or non-pivoted position, the pulley cord 84 C is tensioned. One of the cage stops 84 CS is affixed to the motor cage 84 MC; the complementary cage stop 84 CS is affixed to the deck 82 . The complementary cage stops 84 CS are in abutting engagement when the deck 82 is in the ‘down’ position during normal cleaning operations due to the weight of the self-adjusting cleaning head subsystem 80 .
[0059] During normal cleaning operations, the torque generated by the motor 48 is transferred to the dual-stage brush subassembly 90 by means of the shaft 48 S through the dual-output gearbox 48 B. The motor cage assembly is prevented from rotating by the counter-acting torque generated by the pulley cord 84 C on the pulley 84 P. When the resistance encountered by the rotating brushes changes, the deck height will be adjusted to compensate for it. If for example, the brush torque increases as the machine rolls from a smooth floor onto a carpet, the torque output of the motor 48 will increase. In response to this, the output torque of the motor 48 will increase. This increased torque overcomes the counter-acting torque exerted by the pulley cord 84 C on the pulley 84 P. This causes the pulley 84 P to rotate, effectively pulling itself up the pulley cord 84 C. This in turn, pivots the deck about the pivot axis, raising the brushes, reducing the friction between the brushes and the floor, and reducing the torque required by the dual-stage brush subassembly 90 . This continues until the torque between the motor 48 and the counter-acting torque generated by the pulley cord 84 C on the pulley 84 P are once again in equilibrium and a new deck height is established.
[0060] In other words, during the adjustment mode, the foregoing torque transfer mechanism is interrupted since the shaft 48 S is essentially stationary. This condition causes the motor 48 to effectively rotate about the shaft 48 S. Since the motor 48 is non-rotatably secured to the motor cage 84 MC, the motor cage 84 MC, and concomitantly, the pulley 84 P, rotate with respect to the mounting brackets 82 MB. The rotational motion imparted to the pulley 84 P causes the pulley 84 P to ‘climb up’ the pulley cord 84 PC towards the anchor member 84 AM. Since the motor cage 84 MC is effectively mounted to the forward lip of the deck 82 by means of the mounting brackets 82 MB, this movement of the pulley 84 P causes the deck 82 to pivot about its pivot axis 82 PA to an “up” position (see FIG. 4C ). This pivoting motion causes the forward portion of the deck 82 to move away from surface over which the autonomous floor-cleaning robot is traversing.
[0061] Such pivotal movement, in turn, effectively moves the dual-stage brush assembly 90 away from the surface it was in contact with, thereby permitting the dual-stage brush assembly 90 to speed up and resume a steady-state rotational speed (consistent with the constant torque transferred from the motor 48 ). At this juncture (when the dual-stage brush assembly 90 reaches its steady-state rotational speed), the weight of the forward edge of the deck 82 (primarily the motor 48 ), gravitationally biases the deck 82 to pivot back to the ‘down’ or normal state, i.e., planar with the bottom surface of the chassis 21 , wherein the complementary cage stops 84 CS are in abutting engagement.
[0062] While the deck adjusting subassembly 84 described in the preceding paragraphs is the preferred pivoting mechanism for the autonomous floor-cleaning robot 10 according to the present invention, one skilled in the art will appreciate that other mechanisms can be employed to utilize the torque developed by the motor 48 to induce a pivotal movement of the deck 82 in the adjustment mode. For example, the deck adjusting subassembly could comprise a spring-loaded clutch mechanism such as that shown in FIG. 4C (identified by reference characters SLCM) to pivot the deck 82 to an “up” position during the adjustment mode, or a centrifugal clutch mechanism or a torque-limiting clutch mechanism. In other embodiments, motor torque can be used to adjust the height of the cleaning head by replacing the pulley with a cam and a constant force spring or by replacing the pulley with a rack and pinion, using either a spring or the weight of the cleaning head to generate the counter-acting torque.
[0063] The removable dust cartridge 86 provides temporary storage for macroscopic and microscopic particulates swept up by operation of the dual-stage brush assembly 90 and microscopic particulates drawn in by the operation of the vacuum assembly 100 . The removable dust cartridge 86 is configured as a dual chambered structure, having a first storage chamber 86 SC 1 for the macroscopic and microscopic particulates swept up by the dual-stage brush assembly 90 and a second storage chamber 86 SC 2 for the microscopic particulates drawn in by the vacuum assembly 100 . The removable dust cartridge 86 is further configured to be inserted in combination with the deck 82 so that a segment of the removable dust cartridge 86 defines part of the rear external sidewall structure of the autonomous floor-cleaning robot 10 .
[0064] As illustrated in FIGS. 5A-5B , the removable dust cartridge 86 comprises a floor member 86 FM and a ceiling member 86 CM joined together by opposed sidewall members 86 SW. The floor member 86 FM and the ceiling member 86 CM extend beyond the sidewall members 86 SW to define an open end 86 OE, and the free end of the floor member 86 FM is slightly angled and includes a plurality of baffled projections 86 AJ to remove debris entrained in the brush mechanisms of the dual-stage brush assembly 90 , and to facilitate insertion of the removable dust cartridge 86 in combination with the deck 82 as well as retention of particulates swept into the removable dust cartridge 86 . A backwall member 86 BW is mounted between the floor member 86 FM and the ceiling member 86 CM distal the open end 86 OE in abutting engagement with the sidewall members 86 SW. The backwall member 86 BW has an baffled configuration for the purpose of deflecting particulates angularly therefrom to prevent particulates swept up by the dual-stage brush assembly 90 from ricocheting back into the brush assembly 90 . The floor member 86 FM, the ceiling member 86 CM, the sidewall members 86 SW, and the backwall member 86 BW in combination define the first storage chamber 86 SC 1 .
[0065] The removable dust cartridge 86 further comprises a curved arcuate member 86 CAM that defines the rear external sidewall structure of the autonomous floor-cleaning robot 10 . The curved arcuate member 86 CAM engages the ceiling member 86 CM, the floor member 86 F and the sidewall members 86 SW. There is a gap formed between the curved arcuate member 86 CAM and one sidewall member 86 SW that defines a vacuum inlet 86 VI for the removable dust cartridge 86 . A replaceable filter 86 RF is configured for snap fit insertion in combination with the floor member 86 FM. The replaceable filter 86 RF, the curved arcuate member 86 CAM, and the backwall member 86 BW in combination define the second storage chamber 86 SC 1 .
[0066] The removable dust cartridge 86 is configured to be inserted between the opposed spaced-apart sidewalls 82 SW of the deck 82 so that the open end of the removable dust cartridge 86 aligns with the lateral aperture 82 LA formed in the deck 82 . Mounted to the outer surface of the ceiling member 86 CM is a latch member 86 LM, which is operative to engage a complementary shoulder formed in the upper surface of the deck 82 to latch the removable dust cartridge 86 in integrated combination with the deck 82 .
[0067] The bail 88 comprises one or more narrow gauge wire structures that overlay the dual-stage brush assembly 90 . For the described embodiment, the bail 88 comprises a continuous narrow gauge wire structure formed in a castellated configuration, i.e., alternating open-sided rectangles. Alternatively, the bail 88 may comprise a plurality of single, open-sided rectangles formed from narrow gauge wire. The bail 88 is designed and configured for press fit insertion into complementary retaining grooves 88 A, 88 B, respectively, formed in the deck 82 immediately adjacent both sides of the dual-stage brush assembly 90 . The bail 88 is operative to shield the dual-stage brush assembly 90 from larger external objects such as carpet tassels, tufted fabric, rug edges, during cleaning operations, i.e., the bail 88 deflects such objects away from the dual-stage brush assembly 90 , thereby preventing such objects from becoming entangled in the brush mechanisms.
[0068] The dual-stage brush assembly 90 for the described embodiment of FIG. 3A comprises a flapper brush 92 and a main brush 94 that are generally illustrated in FIG. 6 . Structurally, the flapper brush 92 and the main brush 94 are asymmetric with respect to one another, with the main brush 94 having an O.D. greater than the O.D. of the flapper brush 92 . The flapper brush 92 and the main brush 94 are mounted in the deck 82 recess, as described below in further detail, to have minimal spacing between the sweeping peripheries defined by their respective rotating elements. Functionally, the flapper brush 92 and the main brush 94 counter-rotate with respect to one another, with the flapper brush 92 rotating in a first direction that causes macroscopic particulates to be directed into the removable dust cartridge 86 and the main brush 94 rotating in a second direction, which is opposite to the forward movement of the autonomous floor-cleaning robot 10 , that causes macroscopic and microscopic particulates to be directed into the removable dust cartridge 86 . In addition, this rotational motion of the main brush 94 has the secondary effect of directing macroscopic and microscopic particulates towards the pick-up zone of the vacuum assembly 100 such that particulates that are not swept up by the dual-stage brush assembly 90 can be subsequently drawn up (ingested) by the vacuum assembly 100 due to movement of the autonomous floor-cleaning robot 10 .
[0069] The flapper brush 92 comprises a central member 92 CM having first and second ends. The first and second ends are designed and configured to mount the flapper brush 92 in rotatable combination with the deck 82 and a first output port 48 B O1 of the dual output gearbox 48 B, respectively, such that rotation of the flapper brush 92 is provided by the torque transferred from the electric motor 48 (the gearbox 48 B is configured so that the rotational speed of the flapper brush 92 is relative to the speed of the autonomous floor-cleaning robot 10 —the described embodiment of the robot 10 has a top speed of approximately 0.9 ft/sec). In other embodiments, the flapper brush 92 rotates substantially faster than traverse speed either in relation or not in relation to the transverse speed. Axle guards 92 AG having a beveled configuration are integrally formed adjacent the first and second ends of the central member 92 CM for the purpose of forcing hair and other similar matter away from the flapper brush 92 to prevent such matter from becoming entangled with the ends of the central member 92 CM and stalling the dual-stage brush assembly 90 .
[0070] The brushing element of the flapper brush 92 comprises a plurality of segmented cleaning strips 92 CS formed from a compliant plastic material secured to and extending along the central member 92 CM between the internal ends of the axle guards 92 AG (for the illustrated embodiment, a sleeve, configured to fit over and be secured to the central member 92 CM, has integral segmented strips extending outwardly therefrom). It was determined that arranging these segmented cleaning strips 92 CS in a herringbone or chevron pattern provided the optimal cleaning utility (capability and noise level) for the dual-stage brush subassembly 90 of the autonomous floor-cleaning robot 10 according to the present invention. Arranging the segmented cleaning strips 92 CS in the herringbone/chevron pattern caused macroscopic particulate matter captured by the strips 92 CS to be circulated to the center of the flapper brush 92 due to the rotation thereof. It was determined that cleaning strips arranged in a linear/straight pattern produced a irritating flapping noise as the brush was rotated. Cleaning strips arranged in a spiral pattern circulated captured macroscopic particulates towards the ends of brush, which resulted in particulates escaping the sweeping action provided by the rotating brush.
[0071] For the described embodiment, six (6) segmented cleaning strips 92 CS were equidistantly spaced circumferentially about the central member 92 CM in the herringbone/chevron pattern. One skilled in the art will appreciate that more or less segmented cleaning strips 92 CS can be employed in the flapper brush 90 without departing from the scope of the present invention. Each of the cleaning strips 92 S is segmented at prescribed intervals, such segmentation intervals depending upon the configuration (spacing) between the wire(s) forming the bail 88 . The embodiment of the bail 88 described above resulted in each cleaning strip 92 CS of the described embodiment of the flapper brush 92 having five (5) segments.
[0072] The main brush 94 comprises a central member 94 CM (for the described embodiment the central member 94 CM is a round metal member having a spiral configuration) having first and second straight ends (i.e., aligned along the centerline of the spiral). Integrated in combination with the central member 94 CM is a segmented protective member 94 PM. Each segment of the protective member 94 PM includes opposed, spaced-apart, semi-circular end caps 94 EC having integral ribs 94 IR extending therebetween. For the described embodiment, each pair of semi-circular end caps EC has two integral ribs extending therebetween. The protective member 94 PM is assembled by joining complementary semi-circular end caps 94 EC by any conventional means, e.g., screws, such that assembled complementary end caps 94 EC have a circular configuration.
[0073] The protective member 94 PM is integrated in combination with the central member 94 CM so that the central member 94 CM is disposed along the centerline of the protective member 94 PM, and with the first end of the central member 94 CM terminating in one circular end cap 94 EC and the second end of the central member 94 CM extending through the other circular end cap 94 EC. The second end of the central member 94 CM is mounted in rotatable combination with the deck 82 and the circular end cap 94 EC associated with the first end of the central member 94 CM is designed and configured for mounting in rotatable combination with the second output port 48 B O2 of the gearbox 48 B such that the rotation of the main brush 94 is provided by torque transferred from the electric motor 48 via the gearbox 48 B.
[0074] Bristles 94 B are set in combination with the central member 94 CM to extend between the integral ribs 94 IR of the protective member 94 PM and beyond the O.D. established by the circular end caps 94 EC. The integral ribs 94 IR are configured and operative to impede the ingestion of matter such as rug tassels and tufted fabric by the main brush 94 .
[0075] The bristles 94 B of the main brush 94 can be fabricated from any of the materials conventionally used to form bristles for surface cleaning operations. The bristles 94 B of the main brush 94 provide an enhanced sweeping capability by being specially configured to provide a “flicking” action with respect to particulates encountered during cleaning operations conducted by the autonomous floor-cleaning robot 10 according to the present invention. For the described embodiment, each bristle 94 B has a diameter of approximately 0.010 inches, a length of approximately 0.90 inches, and a free end having a rounded configuration. It has been determined that this configuration provides the optimal flicking action. While bristles having diameters exceeding approximately 0.014 inches would have a longer wear life, such bristles are too stiff to provide a suitable flicking action in the context of the dual-stage brush assembly 90 of the present invention. Bristle diameters that are much less than 0.010 inches are subject to premature wear out of the free ends of such bristles, which would cause a degradation in the sweeping capability of the main brush. In a preferred embodiment, the main brush is set slightly lower than the flapper brush to ensure that the flapper does not contact hard surface floors.
[0076] The vacuum assembly 100 is independently powered by means of the electric motor 46 . Operation of the vacuum assembly 100 independently of the self-adjustable brush assembly 90 allows a higher vacuum force to be generated and maintained using a battery-power source than would be possible if the vacuum assembly were operated in dependence with the brush system. In other embodiments, the main brush motor can drive the vacuum. Independent operation is used herein in the context that the inlet for the vacuum assembly 100 is an independent structural unit having dimensions that are not dependent upon the “sweep area” defined by the dual-stage brush assembly 90 .
[0077] The vacuum assembly 100 , which is located immediately aft of the dual-stage brush assembly 90 , i.e., a trailing edge vacuum, is orientated so that the vacuum inlet is immediately adjacent the main brush 94 of the dual-stage brush assembly 90 and forward facing, thereby enhancing the ingesting or vacuuming effectiveness of the vacuum assembly 100 . With reference to FIGS. 7A , 7 B, the vacuum assembly 100 comprises a vacuum inlet 102 , a vacuum compartment 104 , a compartment cover 106 , a vacuum chamber 108 , an impeller 110 , and vacuum channel 112 . The vacuum inlet 102 comprises first and second blades 102 A, 102 B formed of a semi-rigid/compliant plastic or elastomeric material, which are configured and arranged to provide a vacuum inlet 102 of constant size (lateral width and gap-see discussion below), thereby ensuring that the vacuum assembly 100 provides a constant air inflow velocity, which for the described embodiment is approximately 4 m/sec.
[0078] The first blade 102 A has a generally rectangular configuration, with a width (lateral) dimension such that the opposed ends of the first blade 102 A extend beyond the lateral dimension of the dual-stage brush assembly 90 . One lateral edge of the first blade 102 A is attached to the lower surface of the deck 82 immediately adjacent to but spaced apart from, the main brush 94 (a lateral ridge formed in the deck 82 provides the separation therebetween, in addition to embodying retaining grooves for the bail 88 as described above) in an orientation that is substantially symmetrical to the fore-aft diameter of the autonomous floor-cleaning robot 10 . This lateral edge also extends into the vacuum compartment 104 where it is in sealed engagement with the forward edge of the compartment 104 . The first blade 102 A is angled forwardly with respect to the bottom surface of the deck 82 and has length such that the free end 102 A FE of the first blade 102 A just grazes the surface to be cleaned.
[0079] The free end 102 A FE has a castellated configuration that prevents the vacuum inlet 102 from pushing particulates during cleaning operations. Aligned with the castellated segments 102 CS of the free end 102 A FE , which are spaced along the width of the first blade 102 A, are protrusions 102 P having a predetermined height. For the prescribed embodiment, the height of such protrusions 102 P is approximately 2 mm. The predetermined height of the protrusions 102 P defines the “gap” between the first and second blades 102 A, 102 B.
[0080] The second blade 102 B has a planar, unitary configuration that is complementary to the first blade 102 A in width and length. The second blade 102 B, however, does not have a castellated free end; instead, the free end of the second blade 102 B is a straight edge. The second blade 102 B is joined in sealed combination with the forward edge of the compartment cover 106 and angled with respect thereto so as to be substantially parallel to the first blade 102 A. When the compartment cover 106 is fitted in position to the vacuum compartment 104 , the planar surface of the second blade 102 B abuts against the plurality of protrusions 102 P of the first blade 102 A to form the “gap” between the first and second blades 102 A, 102 B.
[0081] The vacuum compartment 104 , which is in fluid communication with the vacuum inlet 102 , comprises a recess formed in the lower surface of the deck 82 . This recess includes a compartment floor 104 F and a contiguous compartment wall 104 CW that delineates the perimeter of the vacuum compartment 104 . An aperture 104 A is formed through the floor 104 , offset to one side of the floor 104 F. Due to the location of this aperture 104 A, offset from the geometric center of the compartment floor 104 F, it is prudent to form several guide ribs 104 GR that project upwardly from the compartment floor 104 F. These guide ribs 104 GR are operative to distribute air inflowing through the gap between the first and second blades 102 A, 102 B across the compartment floor 104 so that a constant air inflow is created and maintained over the entire gap, i.e., the vacuum inlet 102 has a substantially constant ‘negative’ pressure (with respect to atmospheric pressure).
[0082] The compartment cover 106 has a configuration that is complementary to the shape of the perimeter of the vacuum compartment 104 . The cover 106 is further configured to be press fitted in sealed combination with the contiguous compartment wall 104 CW wherein the vacuum compartment 104 and the vacuum cover 106 in combination define the vacuum chamber 108 of the vacuum assembly 100 . The compartment cover 106 can be removed to clean any debris from the vacuum channel 112 . The compartment cover 106 is preferable fabricated from a clear or smoky plastic material to allow the user to visually determine when clogging occurs.
[0083] The impeller 110 is mounted in combination with the deck 82 in such a manner that the inlet of the impeller 110 is positioned within the aperture 104 A. The impeller 110 is operatively connected to the electric motor 46 so that torque is transferred from the motor 46 to the impeller 110 to cause rotation thereof at a constant speed to withdraw air from the vacuum chamber 108 . The outlet of the impeller 110 is integrated in sealed combination with one end of the vacuum channel 112 .
[0084] The vacuum channel 112 is a hollow structural member that is either formed as a separate structure and mounted to the deck 82 or formed as an integral part of the deck 82 . The other end of the vacuum channel 110 is integrated in sealed combination with the vacuum inlet 86 VI of the removable dust cartridge 86 . The outer surface of the vacuum channel 112 is complementary in configuration to the external shape of curved arcuate member 86 CAM of the removable dust cartridge 86 .
[0085] A variety of modifications and variations of the present invention are possible in light of the above teachings. For example, the preferred embodiment described above included a cleaning head subsystem 80 that was self-adjusting, i.e., the deck 82 was automatically pivotable with respect to the chassis 21 during the adjustment mode in response to a predetermined increase in brush torque of the dual-stage brush assembly 90 . It will be appreciated that another embodiment of the autonomous floor-cleaning robot according to the present invention is as described hereinabove, with the exception that the cleaning head subsystem is non-adjustable, i.e., the deck is non-pivotable with respect to the chassis. This embodiment would not include the deck adjusting subassembly described above, i.e., the deck would be rigidly secured to the chassis. Alternatively, the deck could be fabricated as an integral part of the chassis—in which case the deck would be a virtual configuration, i.e., a construct to simplify the identification of components comprising the cleaning head subsystem and their integration in combination with the robot.
[0086] It is therefore to be understood that, within the scope of the appended claims, the present invention may be practiced other than as specifically described herein.
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A floor-cleaning robot includes a wheeled housing having a perimeter, a motor drive operably connected to wheels of the housing to move the robot across a floor surface, and a bumper responsive to obstacles encountered by the robot. A controller is in electrical communication with both the bumper and the motor drive and is configured to control the motor drive to maneuver the robot to avoid detected obstacles across the floor surface during a floor-cleaning operation. A driven cleaning brush, rotatable about an axis substantially parallel to an underside of the housing, is disposed substantially across a central region of the underside and is positioned to brush the floor surface as the robot is moved across the floor surface. Additionally, a driven side brush extending beyond the perimeter is positioned to brush floor surface debris from beyond the perimeter toward a projected path of the driven cleaning brush.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] Not applicable.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] The present invention relates to toilets, and particular to pressure toilets with siphon assist.
[0004] Achieving an effective flush of a toilet when the bowl is filled with feces, toilet paper, and other solids can be difficult, particularly with a low water consumption toilet. It is common, again especially with some low water consumption toilets, for consumers to flush the toilet twice or more to clean the bowl to their satisfaction. This is not only frustrating and time consuming for consumers, it subverts the environmental and water conservation efforts in many jurisdictions that regulate water consumption, which in many areas may be no more than 1.6 gallons (6.1 liters) of water per flush.
[0005] Conventional toilets have a bowl and a storage tank, usually formed in one or two main pieces. A serpentine passage, typically referred to as a “trapway”, is positioned behind and below the bowl as conduit for the contents of the bowl to the waste plumbing lines of the building. While the precise configuration of a toilet's trapway varies, all generally include an up leg, which is normally filled with water to “trap” sewer gases downstream thereof, so as to prevent them entering the building interior. Water is maintained in the bowl and the up leg of the trapway by an arched weir or dam of the trapway that is elevated above the opening of the bowl. The trapway thus also helps retain water in the bowl prior to flushing.
[0006] During a flush cycle, water and waste within the bowl are passed up the up leg over the dam, down a down leg and through an outlet to plumbing lines. The mechanism for creating a flush is different when comparing pressure flush toilets and gravity flush toilets. The latter makes use of the air in the down leg and the pressure head in the up leg forced over the dam to establish a siphon in the trapway that draws the water and waste from the bowl and out of the trapway. As the bowl is emptied, air enters the trapway and breaks the siphon, and fresh water from the tank refills the bowl.
[0007] In pressurized toilets, which use one or a combination of line pressure, tank stored pressurized water, or sump pumped water, a pressurized stream of water is injected into the trapway or the bowl to blow the bowl contents through the trapway. A siphon of the type produced in conventional gravity toilets is typically not used in pressurized toilets. However, some pressurized toilets, (e.g. U.S. Pat. No. 6,219,855) do purport to use a siphon as well.
[0008] It is difficult to achieve consistent sustained siphon in the trapway of conventional pressure toilets. This is because the trapways of conventional pressure toilets are typically designed differently than in gravity toilets. In particular, the trapways in pressure toilets usually have a large area down stream from the up leg. This enlarged area accommodates the liquid and bulk waste material that is evacuated rapidly from the bowl and into the trapway by the water jet. Without it, water and waste may be forced back through the up leg and back into the bowl, which may defeat an effective flush.
[0009] Unfortunately, the large space downstream from the up leg thus makes achieving and sustaining a siphon difficult. One reason for this is that the large sectional area in the blow out region of the trapway requires more liquid and waste to fill it. Another reason is that air in the down leg prior to initiation of the flush cycle may be forced back into the up leg through a part of this enlarged region not occupied by the evacuating water and waste.
[0010] Hence, improvements are desired in pressurized toilets with respect to the use of siphons.
SUMMARY OF THE INVENTION
[0011] The invention provides a pressure toilet that provides “as needed” siphon assist, that is during increased bulk loading of the toilet. During normal liquid waste or low bulk flushing, no siphon is generated in the trapway, and the water and light waste in the bowl is adequately evacuated under the force of the pressurized jet of water. An extra volume near or just downstream from the dam is provided to accommodate the blow out from the water jet. Only upon reaching a threshold concentration of bulk waste material in the down leg does the trapway draw a siphon (e.g. when feces and toilet paper are present in the trapway). A horizontal baffle at the lower part of the down leg can assist in the accumulation of bulk waste material of sufficient concentration to establish the siphon in the trapway.
[0012] In one aspect the invention provides a toilet having a bowl and pressurized water supply for injecting pressurized water into the trapway (either directly or passing first through the bowl) that extends between a bowl opening and an outlet opening. The trapway effects a siphon only above a threshold concentration of bulk waste material in the trapway, such that no siphon is generated below the threshold level.
[0013] The trapway has an up leg extending upward and rearward from the bowl opening to a curved water dam region above the bowl opening to a down leg, which slopes downward and forward to communicate with the outlet. An enlarged volume blow-out section of greater sectional area is provided in the trapway just downstream from the up leg or dam so as accommodate the rapid evacuation “blow out” of waste by the pressure jet without causing blow back through the up leg and back into the bowl.
[0014] The threshold bulk waste concentration is preferably between 2 and 5 percent by weight of all material within the trapway apart from the trapway itself. Preferably, the concentration level is taken within the down leg of the trapway. A bulk waste concentration less than this corresponds to light waste loading, including liquid only waste, and by in large no siphon is needed to assist the pressure jet, and a bulk waste concentration at or over this corresponds to significant loading when a siphon can contribute significantly to achieving a sufficient flush.
[0015] The trapway can also have an essentially horizontal baffle extending forward from a rear wall of the down leg adjacent to a lower portion of the down leg. This baffle works to accumulate bulk in the down leg of the trapway so that when significant bulk is to be passed through the trapway the bulk waste concentration threshold can be reached and a siphon can be effected sooner in the flush cycle. The siphon and its early initiation help ensure that the wasted will be evacuated in a single flush, even in low water consumption toilets.
[0016] In preferred forms, the up leg and down leg are separated by a radius between 0.5 and 1 inches (1.3 cm and 2.5 cm) at the dam. The up leg can extend at an angle between 30 and 45 degrees, and the down leg can extend at an angle between 40 and 60, both with respect to a horizontal plane such as would include the bottom of the toilet or the outlet opening. The dam preferably extends at a height above the bottom of the bowl that is between 4 and 6 inches (10.2 cm and 15.2 cm). The horizontal baffle preferably has a ledge length of between 0.5 inches and 2.5 inches (1.3 cm and 6.4 cm) measured from the rear wall of the down leg and a ledge height of between 1 inch and 3.5 inches (2.5 cm and 8.9 cm) measured from the bottom of the down leg.
[0017] The toilet of the present invention exhibits improved bulk flushing characteristics, which can be achieved with low water consumption per flush, preferably 1.4 gallons (5.3 liters), and at a lower flush velocity than is common in pressurized systems, preferably between 8 and 10 meters per second, thereby decreasing flush noise. A suitable minimum ball passage, preferably about 2 inches (5.1 cm) or more, is nevertheless maintained.
[0018] The advantages of the invention will be apparent from the detailed description and drawings. What follows is merely a description of a preferred embodiment of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiment is not intended to be the only embodiment within the scope of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a side elevational view of a toilet trapway according to the present invention, with a toilet that the trapway can used in shown in phantom;
[0020] FIG. 2 is a partial vertical cross-sectional view taken down the front-to-back center line of the rear portion of the toilet of FIG. 1 ;
[0021] FIG. 3 is a partial cross-sectional view taken along line 3 - 3 of FIG. 2 ;
[0022] FIG. 4 is a partial cross-sectional view taken along line 4 - 4 of FIG. 2 ; and
[0023] FIG. 5 is a view showing the trapway diagrammatically.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] FIG. 1 illustrates a pressure toilet 10 having a tank 12 , a bowl 14 , a jet channel 16 (see FIG. 2 ) and a trapway 18 according to the present invention. Except for the trapway, the toilet can be any suitable pressure toilet, such as the two piece low volume flush design shown in FIG. 1 , providing a pressurized water stream in any known manner, including for example using direct water line pressure, accumulating a volume of pressurized water in the tank, or proving a sump pump for pressurizing the tank water.
[0025] U.S. Pat. Nos. 5,305,475 and 5,046,201 disclose examples of pressure assist toilets having mechanisms for generating the water jet suitable for use here. The disclosure of the features for generating and conveying the pressurized water in these patents is hereby incorporated by reference as though fully set forth herein.
[0026] In any such manner, water pressurized to greater than atmospheric pressure is passed from the tank 12 through the jet channel 16 . Typically, the jet channel 16 is a passage formed in the vitreous base of the toilet and wraps around the front of the bowl 14 so that its outlet is directed toward the rear of the toilet. The jet channel 16 can terminate in a bowl sump 20 , the trapway 18 (in an up leg thereof) or at the junction of the trapway 18 and a bowl opening 22 , provided it directs the water jet to force the waste within the bowl into the trapway 18 . In the toilet 10 shown in FIG. 1 , the jet channel 16 terminates at the bowl sump 20 with the water jet passing through opening 23 .
[0027] As shown in FIGS. 1 and 2 , the trapway 18 extends from the bowl opening 22 along a serpentine path in a generally hairpin configuration with an oblong rounded or somewhat cross-section (as shown in FIGS. 3 and 4 ). The base of the toilet 10 has an outlet 24 , preferably contained within an essentially horizontal plane, at the bottom which the trapway 18 that mounts over the open end of a waste plumbing line (not shown). The trapway 18 thus creates a path for contents in the bowl 14 to flow to the waste line during a flush cycle.
[0028] Referring to FIG. 2 , an up leg 26 of the trapway 18 extends back from the bowl opening 22 upward and rearward to a bend, the inside diameter of which forms a weir or water dam 28 , after which point water can pass through the downstream portion of the trapway 18 . At, or immediate downstream from the dam 28 is an enlarged volume “blow out” region 30 which has a larger sectional area to accommodate the waste and water forced rapidly through the up leg 26 by the water jet. Its large size reduces the likelihood of waste blow back into the bowl. A down leg 32 extends from the dam 28 downward and forward down to an opening 34 which aligns with the toilet outlet 24 . The dam 28 follows a tight radius such so as to change the flow direction through the down leg 32 about 180 degrees from the direction of flow through the up leg 26 .
[0029] Adjacent the opening 34 at the bottom end of down leg 32 , the trapway 18 has a short, flat horizontal baffle 36 extending between the rear wall of the down leg 32 . The baffle 36 works to disrupt flow through the down leg 32 . For liquid and very low bulk waste, the baffle 36 improves flow by generating turbulence low in the down leg 32 . For larger bulk waste, the baffle 36 works to accumulate bulk in the down leg 32 to achieve the necessary concentration of bulk material necessary to start a siphon, and to do so earlier in the flush cycle.
[0030] The trapway 18 is configured and sized specifically to consistently achieve a siphon pull within the trapway 18 to assist the water jet when evacuating large amounts of bulk waste from the bowl 14 during a flush cycle. The trapway 18 is further designed to achieve the siphon only when a threshold concentration of bulk material is present within the trapway, that is when sufficient solid waste is present in the trapway 18 . No siphon is established when liquid only or insufficient bulk (below the concentration threshold) is present in the trapway. The bulk waste concentration within the down leg 32 is believed to be of particular significance, and it is in this region that the bulk waste concentration threshold is considered.
[0031] With reference to FIG. 5 , the following Table 1 summarizes the values determined to be acceptable and preferred for the various design parameters of the trapway.
[0000]
TABLE 1
Trapway design parameters
Parameter
Preferred
Range
Trapway dam radius (r)
0.8 in/2 cm
0.5-1.0 in/1.3-2.5 cm
Trapway dam height above
4.85 in/12.3 cm
4.0-6.0 in/10.2-15.2 cm
bowl (h D )
Trapway up leg angle (2 U )
32.5 degrees
30-45 degrees
Trapway down leg angle (2 D )
50 degrees
40-60 degrees
Baffle ledge length (L B )
1.1 in/2.8 cm
0.5-2.5 in/1.3-6.4 cm
Baffle ledge height (h B )
1.2 in/3.0 cm
1-3.5 in/2.5-8.9 cm
Minimum ball passage
2.0 in/5.1 cm
1.5-2.5 in/3.8-6.4 cm
Bulk waste concentration
2.5% by weight
2%-5% by weight
threshold
[0032] The values given for the above parameters are dependent on the volume of water in the bowl as well as the volume and rate of water injected through the jet channel during the flush cycle. These values are given in the following Table 2.
[0000]
TABLE 2
Toilet conditions
Parameter
Value
Bowl volume
0.75 gallons/2.8 liters
Flush volume
1.4 gallons/5.3 liters
Jet velocity
8.5 m/s
[0033] The inventors have determined empirically that the dam 28 radius (r) and the angle (2 U ) of the up leg 26 from horizontal parameters are most sensitive with respect to bulk waste and the ability to achieve a siphon. The angle (2 D ) of the down leg 32 has a moderate effect, as does the location and configuration of the baffle 34 (L B ) and (h B ). The inventors have also determined that a trapway having such configuration can develop a siphon when the bulk waste concentration within the down leg 32 is between 2% and 5% by weight (including liquid mass), with the preferred bulk waste concentration threshold being 2.5% by weight.
[0034] The dam radius (r) between the up leg 26 and the down leg 32 is designed preferably to be between 0.5 and 1.0 inches (1.3-2.5 cm). The up leg 26 is designed to extend up and back away from the bowl opening 22 between at an angle 2 U 30 and 45 degrees from horizontal. And, the down leg 32 is preferably 40 to 60 degrees from horizontal. The inventors have determined empirically that for the above stated parameters, a dam radius (r) of 0.8 inches (2 cm), an up leg angle (2 U ) of 32.5 degrees and a down leg angle (2 D ) of 50 degrees are most preferred. These values are also selected to help develop a flow profile that carries the bulk material over and away form the inner bend of the water dam 28 and into the down leg 32 .
[0035] The baffle 34 preferably extends a length (L B ) of between 0.5 and 2.5 inches (1.3-6.4 cm) at a height (h B ) of between 1 and 3.5 inches (2.5-8.9 cm). The preferred values for these parameters corresponding to those of the other parameters stated above are 1.1 inches (2.8 cm) and 1.2 inch (3.0 cm), respectively. These values provide for a sufficient interruption of flow through the down leg 32 so as to build up bulk material therein without closing off the passage excessively. The baffle ledge height and length will vary up or down proportionally to the radius of the down leg.
[0036] Empirical testing has established that a toilet with a trapway of the present invention has improved overall bulk material performance compared to otherwise similar conventional pressure toilets. Its improved ability to remove bulk material allows the toilet to operate at very a low flush volume, 1.4 gallons (5.3 liters) per flush compared to 1.6 gallons (6.1 liters) per flush in conventional toilets, and at a lower jet velocity, preferably 8-10 meters per second (more preferably 8.5 m/s). Thus, the improved toilet consumes less water, operates quieter and handles bulk waste better than conventional pressure toilets.
[0037] The empirical studies conducted to establish the improved bulk handing of the toilet and trapway of the present invention include pulp pad, pulp ball and paste testing, commonly performed by one or more participants in the industry to test the flush performance of a toilet. The present toilet has shown at least a 15%, and in some cases a 33%, improvement in the number of pulp pads (for example made of multiple sections of multi-ply toilet paper) able to be evacuated from the bowl in a single flush when compared to conventional pressure toilets. Tests of paper ball loading, (toilet paper crumpled into a ball) have shown that the present toilet can evacuate on the first flush about 90% of 50 paper balls and 50% of 60 paper balls, with the remainder being removed on the second flush and without any plugging of the trapway. Such results are not known to have been replicated in conventional pressure toilets. It should be noted that a 50 1.5-2 inch (3.8-5.1 cm) paper balls of single-ply toilet paper represents roughly a 4% bulk material concentration.
[0038] It should be appreciated that a preferred embodiment of the invention has been described above. However, many modifications and variations to the preferred embodiment will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiment. To ascertain the full scope of the invention, the following claims should be referenced.
INDUSTRIAL APPLICABILITY
[0039] The invention provides a pressure toilet with an improved trapway design allowing the toilet to more effectively flush bulk waste material by establishing siphonic pull in the trapway when sufficient bulk material is present within the trapway.
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A pressure toilet has a trapway providing “as needed” (bulk dependent) siphon assist. During normal liquid waste or low bulk flushing, no siphon is formed in the trapway, and the water and light waste in the bowl are evacuated solely under the force of the pressurized jet of water. A large volume near or just downstream from the dam is provided to accommodate the blow out from the water jet. Only upon reaching a threshold concentration of bulk waste material in the down leg does the trapway draw a siphon. A horizontal baffle at the lower part of the down leg assists in the accumulation of bulk material of sufficient concentration to establish a siphon in the trapway.
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BACKGROUND OF THE INVENTION
[0001] The present invention generally relates to liquid dispensing systems, and, more specifically, to a medical device that makes it possible to use unused contrast material from opened containers safely for subsequent patients.
[0002] There is a great deal of wasted contrast material that is unused during invasive angiographic procedures, such as cardiac catheterization. During invasive angiographic procedures, fixed volume contrast bottles are used. These have fixed amounts of contrast in them, and very often when the bottles are not used completely, the excess goes to waste. The excess can not be reused due to concerns of contamination from patient connected catheters or other devices. This device is designed to prevent contamination by providing a design that allows contrast or other liquid media to flow to the patient while preventing the reverse flow of contaminants from the patient back to the source. This significantly minimized medical waste by allowing more efficient use of liquids like contrast while preventing the spread of disease from patient to patient.
[0003] This disclosure is written to describe a system that can prevent waste of contrast material used during angiographic procedures, but the technology described can be applied to any liquid pharmaceutical or other high value liquid being dispensed from a primary container to a secondary container. As can be seen, there is a need for a device to allow save use of unused fluids for subsequent patients or other uses.
BRIEF SUMMARY OF THE INVENTION
[0004] One aspect of the present invention is a device to be attached to a contrast bottle comprising: a dosing unit having a bottle spike, a multi-function valve, a dispensing tube, and guides; a receiving tube; and a docking station; wherein the dosing unit is attached to a contrast bottle with the bottle spike, the two are added as a unit to the docking station, which holds these firmly in place in a vertical orientation, a receiving tube is advanced through the guides of the dosing unit thus maintaining vertical orientation and also preventing contamination, and the multi-function valve in the dosing unit is opened allowing contrast to flow into the receiving tube (receiver).
[0005] The device can be designed to operate without being connected to an internal or external power supply making it portable and improving reliability by eliminating the need for an external power source.
[0006] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 depicts a side view of the stacked arrangement embodiment of the device;
[0008] FIG. 2 depicts a side view of the side-by-side arrangement embodiment of the device;
[0009] FIG. 3 depicts a side view of an exemplary embodiment of the receiver tube assembly splash and tipping shields with the receiver tube in vertical or horizontal positions;
[0010] FIG. 4 depicts a side view of an exemplary embodiment of the empty port plug and fluid level indicator with the valve in the open or the closed position;
[0011] FIG. 5 depicts a side view of an exemplary embodiment of the check valve;
[0012] FIG. 6 depicts a side view of an exemplary embodiment of the device assembled with components typically used for a catheterization procedure.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0014] Various inventive features are described below that can each be used independently of one another or in combination with other features. However, any single inventive feature may not address many of the problems discussed above or may only address one of the problems discussed above. Further, one or more of the problems discussed above may not be fully addressed by any of the features described below.
[0015] Broadly, embodiments of the present invention generally provide a device to allow the unused portion of contrast or other medical fluid to be used with the next patient. By using a large source of contrast ( 1 ), such as a bottle, with a docking unit ( 2 ), controlled amounts of contrast may be added to a patient line ( 3 ) and then the extra contrast can be used for the next patient with the use of a fresh receiver ( 4 ).
[0016] The basic operating principal of the fluid saver is the fluid is metered from the sterile jar ( 1 ) into the receiving tube or receiver ( 4 ) (see FIG. 1 ). Metering is achieved by sealing between the contrast jar, doser ( 5 ) with multi function valve assembly ( 6 ), and receiver. In the stacked orientation air is purged from the receiver such that the fluid in the jar is supported by the pressure in the air above the fluid in the receiver. As fluid is delivered to the patient the level in the receiver drops causing the air pressure to drop and allowing fluid to flow into the receiver until the pressure due to the gravity on the fluid and the air pressure in the receiver balance one another and flow stop.
[0017] In an alternative embodiment depicted in FIG. 2 , a side by side design ( 7 ) achieves the same basic function by inverting the bottle and drawing the fluid from the bottle using vacuum. The level of the vacuum is balanced by the weight of the column of fluid being sucked out of the bottle. When the pressure differential on the build caused by the vacuum and the weight of the fluid balance the flow stops. When fluid is delivered to the patient the vacuum increases and flow begins again until the pressure balances again.
[0018] The contrast saver comprises four components: the jar of contrast itself ( 1 ), the fluid retainers, doser ( 5 ), and receiver ( 4 ) and patient connected tube ( 3 ) (see FIGS. 1 , 2 and 6 ).
[0019] The doser is attached to a contrast bottle. The doser has an air vent tube ( 8 ) that can be pushed through the rubber stopper of the contrast bottle, as well as a dispensing tube. The doser has a mechanically actuated multi-function valve that opens when the receiving docking tube unit (receiver) is attached. The doser has guides that ensure coaxial and sterile docking with the receiver.
[0020] The docking station has a built in rest for the contrast bottle, as well as a secure mechanical attachment consisting of rollers, levers, springs and hinges as needed to secure the bottle. The docking station also has a system to secure it to an IV pole or other vertical mount comprising a hook, knob, screw and plate. The purpose of the station is to keep the bottle upright and doser upright. This aids in maintaining sterility. The station can also have a UV lamp array that further maintains sterility which encloses the dosing unit and receiver.
[0021] The receiver has a small reservoir ( 9 ) followed by patient tubing to allow contrast material to be used by the angiographer. The receiver trips the mechanical valve when attached to the doser ( FIGS. 3 and 4 ).
[0022] The receiving tube is designed to maintain the sterility of the contrast in the supply by separating the patient connected tube from the supply by an air gap. The shape, length and diameter of the receiving tube can be adjusted to optimize performance. The sides of the receiver can be rigid or flexible. Flexible sides facilitate setting the fluid level allowing the user to squeeze the receiver to eject air as needed. In addition the receiver can have additional features to prevent the contamination of the supply that would occur from tipping, bumping, shaking, or vibration that could possibly occur in a busy hospital setting. FIG. 3 shows one embodiment of a splash preventing shield ( 10 ) that would deflect any patient connected fluid that splashes back down toward the patent connected fluid. In the extreme case when the fluid saver is completely tipped on its side these same features in the receiver act to maintain separation between the contrast supply and the patient connected fluid.
[0023] Also the connection between the receiver and the doser can be through many mechanical means including threads, twist locks, latches, slip fitted parts, and the like, and the seal between the two done with several possible sealing methods including a gasket, o-ring, luer fitting, and the like provided the receiver can be easily removed and a seal with the doser is maintained while the device is in use.
[0024] In one embodiment of the device there is a component within the receiver that assures there is a minimum fluid level in the receiver. The main reason to have this is to prevent air from getting into the patient line when the main contrast supply runs empty. When there is the correct fluid level in the receiver the empty port plug with its attached float ( 12 ) raises with the fluid level (see FIG. 4 ). Connected to the float is a rod that has a feature that acts as a valve ( 13 ) allowing fluid to flow into the patient connected tube. If the fluid level in the receiver drops below a minimum required to operate safely, the flow to the patient connected tube is blocked. If the contrast bottle is empty it can be changed for a new bottle, fluid can be added to the drip chamber, and the procedure can continue.
[0025] Check valves ( 11 ) are a safety feature that can be incorporated into either the patient connected tube or doser to assure fluid always flow in the direction of the patient (see FIG. 5 ). As a safety feature it is best to prevent retrograde flow in the system. Fluid should generally only flow from the sterile supply to the patient and not in the reverse direction.
[0026] The basic design shown can be extended to incorporate a second bottle so that when the first bottle runs empty the device can switch to run off a second bottle so that the first bottle can be changed and the device can continue to switch between two or more containers. This can be done with a sensor on the fluid level that causes a solenoid valve or other valve mechanism to switch bottles.
[0027] Another item is to incorporate a feature into the doser or multi function valve is to add a bottle lock to the valve that connects the patient connected supply bottle to the fluid saver. The lock disengages with the valve in the off position and engages for all other valve positions. The lock can physically engage the bottle or lock the retainers the hold the bottle. There are multiple benefits to this feature. It prevents the bottle from being removed or getting knocked off inadvertently, but also assures the valve is returned to the proper off position before a bottle is removed or replaced.
[0028] As an additional measure to assure sterility is maintained, an ultraviolet (UV) source can be added to the device at either the doser or receiver to intermittently or continuously irradiate the fluid to help maintain the sterile environment within the system.
[0029] An optical fluid level sensor can be added to the system to alert the user that the bottle supply is beginning to run low or is already empty. The detector can be configured to a light-emitting diode (LED) or other visual or audible indication that alerts the user that fluid is running low. LED's can be used to show the device status using color changes or flashing to communicate the status of the device.
[0030] The contract saver system can be designed to be pole mounted like many hospital devices to facilitate positioning or transport, or can also be designed to operate on a table top or other means of support.
[0031] Lastly, the design is not limited by the packaging of the fluid media. The device can be configured to use various types of contract packaging including a bag or other container.
[0032] In one embodiment the device works by allowing small doses of contrast material to be used at any one time. When the next patient arrives, the doser and docking station remain in place, while the receiver is changed for each new patient. The doser and receiver form an airtight seal, so the amount of contrast used will cause the dosing unit to refill the receiver reservoir. The doser has vertical guides in a circular array so that only the receiving tube may be advanced and attached, aiding sterility. The docking station provides a firm platform for the entire unit, preventing loss of sterility as well as providing UV irradiation to further aid in maintaining sterility. The multifunction valve is important in initially setting up the proper fluid level in the receiver, as well as adjusting the fluid level as needed during the procedure, to maintain an optimal fluid level in the receiver. In addition, at the anticipated end of the procedure, the valve can be set to “drain” position (not pictured, see description below), which will empty the receiver of all remaining contrast and lock the supply bottle. In this way, additional contrast material may be saved rather than discarded in the receiver at the end of the procedure.
[0033] In order to use the device, a contrast bottle is perforated with the bottle spike of the dosing unit. The two are added (as a unit) to the docking station, which holds these firmly in place, and in a vertical orientation. A receiving unit is then advanced through the vertical guides of the doser, maintaining vertical orientation and also preventing contamination. When the airtight seal is ensured, the valve in the doser is opened allowing contrast to flow into the receiver. The multi-function valve is operated to adjust the fluid level in the receiver. When contrast is withdrawn from the receiver with the multi-function valve in the operating position, the level in the receiver will fall, and more contrast will flow from the doser into the receiver through the contrast supply tube in the doser. The three operating positions for the multifunction valve are “fill”, “operate”, and “off”. An additional “drain” position is feasible using the multifunction valve, (not shown) but may be useful for lowering the level of contrast in the case of overfilling.
[0034] The device set up for use is shown in FIG. 6 . Included are a manifold ( 14 ), dump bag ( 15 ), fittings ( 16 ), syringe ( 17 ), and catheter ( 18 ). These components are depicted to show how the fluid saver can be used with the materials that are typically used for a catheterization procedure. Use of the fluid saver does not require any change to standard materials or surgical procedures. The only change is the advantage that the contrast bottle does not need to be changed with each patient allowing all the contrast to be used resulting in significant cost savings.
[0035] The invention may be made with routine manufacturing techniques found in the medical devices/technology field, and could easily be manufactured by any one of a number of medical devices companies. The doser and receiving units may be made of plastic, and the docking station may be made of plastic or aluminum, or any other suitable material.
[0036] The approach described herein is described based on the use of contrast medium. This value of the system is to prevent waste of liquid materials that would otherwise not be allowed to be used based on sterility, mixing, or other contamination concerns. But the same approach can be used for other medications any time drug waste is an issue. Also the use of the device is not limited to medical applications. The approach described in this system is applicable any time contamination between a delivered liquid and its supply must be prevented. The device described can be used in any other field or technology where fluids are being used and contamination free dispensing is needed.
[0037] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
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Herein is described a device that makes it possible to use opened but unused contrast material safely for subsequent patients. During invasive angiographic procedures, fixed contrast bottles are used. These have fixed amounts of contrast in them, and very often when the bottles are not used completely, the excess goes to waste. The present device allows the unused portion to be used with the next patient. By using a large source of contrast, such as a bottle, with a docking unit, controlled amounts of contrast may be added to a patient line and then the extra contrast may be used for the next patient, with the use of a fresh receiver. The docking unit comprises a dosing unit and a receiver.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of pending International patent application PCT/EP2007/056613 filed on Jun. 30, 2007, which designates the United States and claims priority from European patent application 06116486.9 filed on Jun. 30, 2006, the content of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention concerns a ship for use at high speed and/or heavy seas having a single long and slender hull, a bow and the aft end of the hull has a flat or slightly V-shaped bottom with at least one aft rudder, one or more propellers and/or water jets as propulsions means whereby the foreship has a draught that is equal or more than the draught of the aft end characterized in that the bow has a control surface that converts the water flow along the forward moving ship into an adjustable lateral force.
BACKGROUND OF THE INVENTION
[0003] For most ships of such design the condition of sailing in relative large stern quartering or following waves can become dangerous due to the occurrence of “broaching”. Broaching is the peculiar ship behaviour, which consists of a coupled yaw-, sway-and roll motion. Ships may experience this broach motion in the described wave condition and once it occurs it can lead to seriously large roll angles and eventually end in a “capsize”.
[0004] The broaching phenomenon may be roughly explained as follows: In stern quartering and following waves the ship stern is lifted asymmetrically by the incoming wave and it starts the ship to heel (and also pitch). Broaching is particularly prone in waves with a wave length close to the ship length. So simultaneously the ship puts its bow in the face of the (next) wave. Caused by the asymmetry of the hull due to the introduced heeling angle and the directionally destabilizing effect of the now deeply immersed bow sections the ship starts to yaw. Combined with the forward speed this may lead to an increase in the heeling angle which on its turn worsens the hull asymmetry and therewith to further course instability. This may lead to the ship coming beam side to the waves in principal a potentially dangerous situation as it may lead to an even further increase in heel.
[0005] With fast ships this broaching phenomenon may be en-countered more frequently than with regular ships and may have more serious effects because fast ships are generally smaller and sail therefore in relatively larger waves. Also the high forward speed worsens the heeling influence induced by the centrifugal forces once the ship is in a turn and the encounter frequency between the ship and the following waves. In particular the longer and higher waves may have a lower frequency making their impact bigger.
[0006] Ships are normally directionally controlled by either a helmsman or an autopilot. In general the applied control is aimed at keeping the ship on a preset course. From experience, full scale and model scale measurements it is known that this directional control applied in following waves worsens the broaching behavior of the ship, due to the unfavourable phase between the steering force applied and the herewith induced heeling moment.
SUMMARY OF THE INVENTION
[0007] In order to overcome these disadvantages, according to the invention is a ship in accordance with the claims hereof. In this way the resistance against broaching is increased by using the additional control surface for directional control and to make beneficial use of the forces generated by this surface for controlling the roll and sway motion. By applying a control surface in the most forward position as feasible, this control surface may be regarded as an additional control surface for controlling both yaw and heel simultaneously. Then the following improvement occurs: In the situation that the ship sails in stern quartering waves from starboard the stern can be lifted by a wave where after the ship starts to heel to port. The asymmetry of the hull underwater shape induces a yawing moment trying to turn the ship to starboard. Corrective action is applied on the control surface near the bow to correct this course change and the force asked for is a lateral force directed to port. This force implies a rolling motion to starboard and so de-creasing the heeling angle.
[0008] In accordance with another embodiment of the invention a ship of this design is especially favourably for the application of this invention. Such a ship is known from the publication Keuning, J. A.; Toxopeus, S.; Pinkster, J.; The effect of bow-shape on the sea keeping performance of a fast monohull; Proceedings of FAST 2001 conference, September 2001; page 197-206; ISBN 0 903055 70 8, publisher The Royal Institute of Naval Architects. In this publication the ship is described as the AXE BOW design. The increased draught and increased freeboard makes the ship suitable for sailing through heavy seas while ensuring that the control surface remains in heavy seas sufficiently submerged.
[0009] In accordance with another embodiment of the invention the more or less vertical bow is particularly suitably for incorporating a control surface according to the invention.
[0010] In accordance with another embodiment of the invention this fillet radius makes it possible to reduce the length of the ship and so reducing the wet surface and the flow resistance without disadvantageously influencing the ships behavior in waves.
[0011] In accordance with another embodiment of the invention this improves the ships behavior in heavy seas as the added resistance in waves is reduced.
[0012] In accordance with another embodiment of the invention this makes for a simple construction with effective steering and control capabilities.
[0013] In accordance with another embodiment of the invention this makes for an easy construction with good water flow along the hull, thereby minimizing additional drag when not activated.
[0014] In accordance with another embodiment of the invention this embodiment combines at high speeds good control capabilities with high efficiency.
[0015] In accordance with another embodiment of the invention the reducing of the heeling and broaching can be combined in an easy way.
[0016] In accordance with another embodiment of the invention the use of the control surface can be manually adapted to the changing circumstances and wave conditions.
[0017] In accordance with another embodiment of the invention the use of the control surface is adapted automatically to the changing circumstances and wave conditions.
[0018] In accordance with another embodiment of the invention the control surface is only activated when its use improves the ships behaviour.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The invention will be explained in more detail below with reference to several exemplary embodiments by means of a drawing, in which:
[0020] FIG. 1 shows a perspective view of a ship according a first embodiment of the invention,
[0021] FIG. 2 shows a body plan of the design of the ship according to the invention, whereby FIG. 2 a shows the various cross sections, FIG. 2 b shows the side view and FIG. 2 c shows the bottom view,
[0022] FIGS. 3 and 4 show the ship of FIG. 1 respectively from behind and from the top with schematically an indication of the forces in waves,
[0023] FIG. 5 a shows the bow of the ship of FIG. 1 with the first embodiment of the control surface in perspective view, FIG. 5 b show the same embodiment in front view and FIG. 5 c shows a section Vc-Vc of FIG. 5 a,
[0024] FIG. 6 a shows a second embodiment of the control surface in a perspective view and FIG. 6 b shows section VIb-VIb of FIG. 6 a , and
[0025] FIG. 7 a shows a third embodiment of the control surface in a perspective view and FIG. 7 b shows section VIIb-VIIb of FIG. 7 a.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 shows a ship 1 which is designed in accordance with the body plan according to FIG. 2 . The ship 1 is designed for high speeds and has a single long and slender hull, whereby the length of the hull is at least five times the beam and for longer ships as much as seven to eight times the beam. In shorter ships the beam is relatively larger as the hull must include the propulsion means and a wider beam ensures that there remains sufficient stability. The ship 1 in an aft ship 11 has one or more propellers 9 and one or more aft rudders 10 . For maneuvering at low speed there is a bow thruster 6 in a foreship 3 near a bow 4 . The lay out on deck is as usual for instance with a wheel house 2 . In the bow 4 there is a bow rudder 5 of which the function will be explained later.
[0027] As can be seen in FIG. 2 the hull of the ship 1 has a special design, in more detail the design is such that a reduction of the Froude Kriloff forces in particular in the foreship 3 is achieved by minimizing the change in momentaneous submerged volume of the hull with sides 8 whilst it makes larger relative motions relative to the water level due to waves or the ships motions.
[0028] This results in a design applying sides 8 as much as feasible. A further measure in the design is to reduce the change in waterline beam of the sections in particular in the foreship whilst it makes the foresaid larger relative motions. This implies there is a minimal flare in the bow sections and a bow 4 has a more or less vertical line or the bow 4 extends less than 5 degrees forward and backward. By doing so the change of the added mass of the sections is minimized and with that also the changes in the hydrodynamic lift in the foreship 3 are minimized. By increasing the free board and bringing the deck line higher towards the bow 4 in the foreship 3 sufficient reserve buoyancy is guaranteed.
[0029] The amount of increased shear in the foreship 3 is dependent on ship size, speed and wave climate involved. A downwards sloping centre line towards the foreship 3 prevents the sections there to leave and re-enter the water whilst the ship 1 is performing larger relative motions. The amount of negative slope in the bottom 7 is dependent on ship size, speed and wave climate involved. The dead rise angle of the sections from bow to stern is carefully determined in order to minimize exciting forces and yet maintain sufficient hydrodynamic lift with minimal resistance.
[0030] Summarized the shape of the hull is such that the hull is long and slender, there is no flare in the bow sections and the sides 8 at the bow sections are almost vertical. Near the bow 4 the sides 8 make an angle α seen in a horizontal plane which is smaller than 40 degrees. There is an increased sheer forward and down sloping centre line forward and the entry of the waterlines are rounded. In order to reduce the wet surface the bow 4 is rounded with a radius R of at least 0.1 m. Depending on the beam of the ship the radius can be at least 1% of the beam. A further advantage of this radius R is that vortex shedding along the sides 19 of the ship is avoided in this way. This vortex shedding might occur in this design at small yaw angles when the bow is too sharp as is usual with fast ships. The vortex shedding must be avoided as it might lead to course instability. In order to prevent that the rounded bow 3 generates too much stagnation point resistance and/or generates too much spray the radius R is less than 4% of the beam.
[0031] FIGS. 3 and 4 show the behaviour of ship 1 in waves W that approach the aft ship 11 from the stern quarter. A water level s is the normal situation when the ship 1 is level. When waves W approach the aft ship 11 from the port stern quarter the waves create a water level s′. The waves W push against the port side 8 of the aft ship 11 and change the direction of the ships axis 1 from the on course situation indicated with 12 to the off course direction whereby the ships axis is indicated with 1 ′ and the ship is indicated with 13 .
[0032] When the ship 1 is off course the ship 1 can be brought on course using aft rudders 10 . These rudders 10 are then brought in a position as shown in FIGS. 3 and 4 and a force A is generated on the aft rudders 10 . This force creates with the force of the waves W a tilting torque. Summarized the forces A on the aft rudders 10 reinforce the forces of the waves W on the side 8 . If the ship 1 is brought on course using a bow rudder 5 a force B is generated on the bow rudder 5 . This force B has the same direction as the force generated by the waves W and so counteracts the tilting torque of the waves W. Summarized the force B on the bow rudder 5 used for bringing the ship 1 on course reduces the tilting due to the waves W. This advantageous result is only for waves W that are incoming from the stern quarter as for waves W coming in from the front (not shown) using the bow rudder 5 would result in increased tilting.
[0033] The bow rudder 5 is only used when the waves W coming in sideways result in the course change as indicated before when waves are coming in from the stern quarter of the ship 1 . In the situation whereby the ship 1 is designed with its maximum draught in the foreship 3 , as described before, waves W coming in sideways or a few compass points forward will result in the same behaviour and the use of the bow rudder 5 is then also an advantage.
[0034] The ship 1 is provided with means to switch over from steering with the aft rudder 10 to steering with the bow rudder 5 or with both rudders. When steering using an automatic steering system the switching over can be effected by manually indicating to the automatic steering system from which direction waves W are coming in, which steering system will then take this information into account. The automatic steering system can also include an algorithm for calculating the direction from which the waves W are coming in. The automatic system is then provided with sensors for determining the movements of the ship 1 , for instance using gyroscopes.
[0035] FIGS. 5 a , 5 b and 5 c show the bow rudder 5 mounted in the foreship 3 in more detail. The bow rudder 5 is the lowest part of the bow 4 and has a rotation axis 14 which is more or less vertical. The bow rudder 5 is shaped such that when it is in its middle position the contour of the rudder 5 follows the shape of the hull as indicated in FIG. 2 and the water flow F is not influenced by the bow rudder 5 . Part of the bow rudder 5 is in front of the rotation axis 14 so that the torque for rotating the bow rudder 5 is partly balanced, similar as can be used in known rudders. The rotation of the bow rudder 5 is effected in the same manner as usual with known rudders.
[0036] FIGS. 6 a and 6 b show a second embodiment of the bow 4 of the ship 1 . Instead of a conventional rudder located in the bow 4 the lateral forces B for steering the ship 1 are now generated by the flow F along a side flap 16 . On each side of the bow 4 there is a side flap 16 , these side flaps 16 rotate around a more or less vertical axis 17 , which axis 17 is supported at the lowest part of the bow 4 by a support 15 . When not activated the side flaps 16 follow the contour of the foreship 3 and are positioned against a brace 18 . For moving the side flaps 16 so that they can generate an adjustable lateral force B there is a mechanism 19 . This mechanism 19 can be formed by two hinged levers connected to each other and respectively the foreship 3 and the side flap 16 . The hinge connecting these levers can be moved in vertical direction by a hydraulic cylinder (not shown). This hydraulic cylinder can be located above the water level and is con-trolled such that either the one or the other side flap 16 is moved outside the contour of the foreship 3 in order to generate the lateral force B.
[0037] FIGS. 7 a and 7 b show a third embodiment of the bow 4 of ship 1 . A submerged part of the bow 4 now consists of a rotor 20 that can rotate around a more or less vertical rotation axis 21 . For driving the rotor 20 there is a drive 23 that drives the rotor 20 via a transmission 22 . The drive 23 can be electric or hydraulic and can be located above the water level. During rotation the rotor 20 acts as a so called Magnus rotor and generates asymmetric pressure fields at the different sides of the bow 4 so that a lateral force B is the result. By changing the speed of rotation of the rotor 20 the magnitude of the lateral force B can be adjusted.
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A ship for use at high speed and/or heavy seas having a single long and slender hull, a sharp bow and the aft end of the hull has a flat or slightly V-shaped bottom with at least one aft rudder, and at least one propeller or water jet for propulsion whereby the foreship has a draught that is equal or more than the draught of the aft end. The bow has a control surface that converts the water flow along the forward moving ship into an adjustable lateral force.
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FIELD OF THE INVENTION
[0001] This invention relates generally to a storage battery installed in the engine compartment of an automobile where it is exposed to heat at an elevated temperature emanating from the engine, and in particular to a thermal jacket for accommodating and cooling the battery to cause it to operate efficiently.
BACKGROUND OF THE INVENTION AND STATUS OF PRIOR ART
[0002] In the typical automobile propelled by an internal combustion engine, there is placed in the engine compartment adjacent the engine a rechargeable storage battery. This battery supplies dc power for starting the car, for energizing the car lights and for powering other devices requiring dc power.
[0003] Because of the close proximity of the battery to the engine, it is exposed to heat at an elevated temperature emanating from the engine. When the engine has been operating for several hours, the heat of the engine developed during this period and transferred to the storage battery may impair its operation.
[0004] A conventional rechargeable storage battery for an automobile is identified as a lead-acid battery. The reason for this denomination is that the electrolyte of the battery is an acid and its plates are largely formed of a lead-based composition. The positive active electrode material of the battery is lead peroxide and the negative active electrode material is lead sponge.
[0005] When these electrodes are immersed in a sulfuric acid electrolyte (H 2 SO 4 —H 2 O), an electromotive force (EMF) is then developed between the electrodes. In an auto storage battery, each cell thereof produces a nominal voltage of 2 volts. Since the battery must provide a 12 volt output, it includes six 2 volt cells connected in a series. However, the voltage yielded by each storage battery cell is not exactly 2 volts but varies as a function of the concentration of the sulfuric acid electrolyte and its temperature.
[0006] As noted in the section “Storage Battery” in Vol. 17 page 443 of the McGraw-Hill Encyclopedia of Science and Technology, when the concentration of the storage battery electrolyte is 1200 spgr and the electrolyte temperature is at 25° C. (77° F.), then the cell voltage is 2.050V. But when at the same temperature, the acid concentration is 1300 spgr, then the output voltage of the cell increases to 2.148V.
[0007] Variations in the temperature of the electrolyte give rise to less dramatic changes in the cell voltage. Thus a small change in the temperature of the electrolyte produces only a slight change in cell output voltage in the millivolts range. However, should the electrolyte in a battery placed in the engine compartment of an automobile undergo a steep rise in temperature because of intense heat emanating from the engine, then the output of the battery cell may is fall below 2 volts. This results in a drop in the output voltage of the multi-cell battery so that it is then below its nominal 12 volt value. As a consequence, the battery in this overheated condition may be unable to carry out all of its assigned tasks.
[0008] One could try to prevent the electrolyte in a storage battery placed in an engine compartment from overheating by enveloping the battery in a thermal jacket composed of thermal insulation material. But in the environment of an auto engine compartment, a thermal jacket can only function to slow down the rate of heat transfer from the engine to the battery. It cannot prevent a gradual increase in electrolyte temperature resulting from prolonged operation of the engine in the course of which the battery is subjected to heat at high temperature levels.
[0009] In the context of a thermal jacket worn by an individual to keep his body warm in a cold environment, the jacket then functions to reduce the loss of heat from the body whose temperature is internally regulated so that it normally is at a temperature of about 37° C. But a storage battery is not internally heated nor cooled. If, therefore, one wishes to prevent a storage battery in the environment of an automobile engine compartment from overheating, it then becomes necessary to cool the battery.
[0010] It is known in the prior art to cool the battery of a vehicle to prevent it from overheating. Thus U.S. Pat. No. 5,937,664 to Takayoshi et al. (1998) discloses a battery cooling system for a vehicle whose passenger compartment is cooled by an air conditioner. The vehicle battery is placed in a separate chamber and there cooled by air drawn by a cooling fan from the air-conditioned passenger compartment and blown into the battery chamber.
[0011] The practical drawback to this arrangement is that it makes it necessary to create a special chamber for the battery as well to provide an air circulating system between this chamber and the passenger compartment.
SUMMARY OF THE INVENTION
[0012] In view of the foregoing, the main object of this invention is to provide a thermal jacket for an automobile storage battery which acts to cool the battery so as to maintain the temperature of its electrolyte at a level at which the battery operates at optimal efficiency.
[0013] More particularly, an object of this invention is to provide a jacket of the above type whose walls are formed of closed-cell polyurethane foam material having a high degree of thermal resistance whereby transfer of heat from the battery to the engine compartment and vice versa is minimized, and the temperature of the electrolyte in the battery is mainly regulated by a coolant flowing through the thermal jacket.
[0014] Among the advantages of a jacket in accordance with the invention are the following:
[0015] A. The thermal jacket which accommodates and cools the car battery does not significantly enlarge the space requirements for the battery in the engine compartment. Hence no difficulty is experienced when installing the jacket in the existing space for the battery.
[0016] B. The thermal jacket is formed by four walls of synthetic foam plastic material joined together to create a rectangle, which rectangle can easily be fabricated at a relatively low cost.
[0017] C. The jacket incorporates in one of its walls a heat exchanger through which flows a coolant derived from the existing air conditioner in the vehicle. Hence this arrangement does not substantially add to the cost of the installation.
[0018] D. The thermal jacket improves the performance of the battery and prolongs its effective life.
[0019] Briefly stated, these objects are attained in a thermal jacket adapted to accommodate and cool the storage battery placed in the engine compartment of an automobile and exposed to heat at elevated temperatures emanating from the engine. The walls of the rectangular jacket are formed of rigid foam plastic material which thermally insulate the battery. Embedded in one wall of the jacket is a heat exchanger in which there is circulated a refrigerant fluid derived from the air conditioner installed in the vehicle. The heat exchanger acts to cool the battery to maintain the temperature of the electrolyte therein at a level at which the battery operates at optimal efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a better understanding of the invention as well as other objects and features thereof, reference is made to the annexed drawings wherein:
[0021] [0021]FIG. 1 is a top view of a thermal jacket in accordance with the invention for accommodating an automobile storage battery, the jacket being associated with the air-conditioner unit of the auto;
[0022] [0022]FIG. 2 is a prospective view of the jacket;
[0023] [0023]FIG. 3 is a separable view of the heat exchanger included in one wall of the jacket; and
[0024] [0024]FIG. 4 shows a jacket arrangement having embedded in one wall thereof a thermoelectric device to cool the battery, the device being powered by the battery.
DETAILED DESCRIPTION OF THE INVENTION
[0025] First Embodiment: Referring now to FIGS. 1 and 2 of the drawing, shown therein is a standard multi-cell, lead-acid storage battery 10 having output terminals 11 and 12 to provide the 12 volt output required for the dc powered devices in an automobile. As previously explained, the actual dc output of the battery depends on the existing temperature of its electrolyte, which temperature may be such as to reduce the output voltage.
[0026] Battery 10 is installed in the engine compartment of an automobile having an internal combustion engine. The concern of the present invention is with the heat emanating from the engine which when transferred to the electrolyte in the battery will overheat it, with a resultant impairment of the efficiency of the battery. Overheating of the electrolyte for prolonged periods may also shorten the life of the battery.
[0027] In order to maintain the electrolyte contained in battery 10 in a relatively cool state and thereby cause the battery to function at optimal efficiency so that its dc output voltage never falls below 12 volts, battery 10 is nested within a thermal jacket J whose rectangular structure is defined by a pair of long side walls 13 and 14 and a pair of shorter end walls 15 and 16 . The side walls are bonded or otherwise joined to the end walls at the corners of the rectangle. The inner dimensions of jacket J substantially match the outer dimensions of battery 10 . Hence to install the jacket, it is only necessary to telescope it over the battery.
[0028] The walls of jacket J are preferably composed of rigid, closed cell polyurethane foam plastic material having a high degree of thermal resistance and therefore acting as thermal insulation. The use of this material as thermal insulation is well known, as in the thermal insulation included in refrigerated appliances and vehicles.
[0029] Polyurethane resins are produced by the reaction of a disocyanate with at least two active hydrogen atoms, such as diole or diamine. In practice, other thermal insulating materials may be used, such as rigid polyvinyl foam. Embedded in wall 14 of the jacket is a heat exchanger 17 formed by a serpentine tube of thermally-conductive material, such as copper or aluminum. The successive U-shaped branches of the tube lie in a common plane parallel to the planar inner surface in wall 14 . The heat exchanger is provided with an inlet 17 A to receive a coolant fluid, and an outlet 17 B from which the fluid is discharged.
[0030] Heat exchanger 17 is associated with a standard air conditioner unit 18 installed in the automobile. In a unit of this type, the cooling effect takes place in an evaporator where heat from the passenger compartment is absorbed by a low-pressure refrigerant vapor, such as FREON, the vapor being conveyed to a compressor where it is compressed to a high temperature, high-pressure gas. This gas is fed to a condenser in which it is condensed to a high-pressure liquid which flows through an expansion device. In this device it becomes a low-temperature, low-pressure vapor which is fed into the evaporator to complete the cycle. This low-temperature, low-pressure vapor in the first embodiment of the invention functions as the coolant which flows through the tubing of heat exchanger 17 in the thermal jacket J surrounding the storage battery.
[0031] Air conditioner unit 18 , by way of a valve 19 , is coupled to inlet 17 A and outlet 17 B of the heat exchanger 17 whereby the tubing of the heat exchanger is effectively interposed in the fluid line feeding low-temperature vapor into the evaporator of unit 18 . When valve 19 is open, then the cold vapor from the unit flows through the heat exchanger in the jacket. But when valve 19 is closed, the heat exchanger is disconnected from the unit.
[0032] To thermostatically regulate the temperature of the battery which is being cooled by jacket, a heat-sensitive detector 20 is provided which is mounted in the jacket adjacent its inner surface to yield a signal whose magnitude depends on the temperature within the jacket.
[0033] The signal is conveyed to a thermostatic switch 21 which is arranged to actuate valve 19 when the temperature within the jacket reaches a predetermined level. At this point, valve 19 is opened to admit the cooling fluid into the heat exchanger to cool the battery.
[0034] Automatic control of the battery temperature is not essential, unless one wishes to maintain the temperature of the electrolyte at that temperature level at which the battery functions at its optimal efficiency. For the battery to function well, it is only necessary to prevent overheating of its electrolyte.
[0035] Second Embodiment: In the first embodiment of the invention, it is necessary to associate the jacket with the air conditioner installed in the vehicle whose engine compartment contains the battery.
[0036] In the embodiment of the jacket shown schematically in FIG. 4, the cooling means is incorporated in one wall of jacket J. It is constituted by a thermoelectric device of any known type. The typical thermoelectric device is formed of two semiconductive devices having dissimilar characteristics. These are connected electrically in series and are thermally connected in parallel to create two junctions, one being a cold junction and the other a hot junction.
[0037] One semiconductor is of the N-type and the other of the P-type. When a dc voltage is applied across the dissimilar semiconductors, the junction connecting the semiconductors in series to the d-c source becomes intensely cold, whereas the junction thermally connecting the conductors in parallel becomes hot.
[0038] Thermoelectric device 22 which acts to cool the battery derives its dc operating power from the battery itself. The device is situated in wall 14 of the jacket so that its cold junction 22 C faces the battery. Heat from the hot junction of the device is absorbed by a heat sink (not shown).
[0039] To regulate the operation of thermoelectric device 22 , the output of battery 10 is applied to this device through a thermostatic control switch 23 . Coupled to this switch is a heat-sensitive detector 24 which senses the temperature of the battery within the jacket to produce a signal which activates switch 23 only when the electrolyte temperature exceeds a predetermined level.
[0040] When, therefore, thermoelectric device 22 is turned on by switch 23 , it is then powered by battery 10 and serves to cool the battery to prevent overheating of its electrolyte. Thus the battery in effect is self-cooling. In practice, sensor 24 and control switch 23 may be embedded in wall 14 of the jacket, as well as its input terminals to be connected to the battery.
[0041] In the second embodiment, while the power to cool the battery is drawn from the battery itself, little power is required for this purpose in that the battery is thermally insulated from the engine which is the source of heat, and the volume within the jacket to be cooled is small.
[0042] While there has been disclosed preferred embodiments of the invention, it is to be understood that many changes may be made therein without departing from the spirit of the invention.
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A thermal jacket adapted to accommodate and cool a storage battery placed in the engine compartment of an automobile and exposed to heat at elevated temperatures emanating from the engine. The walls of the rectangular jacket are formed of rigid, foam-plastic material which thermally isolate the battery from the engine. Embedded in a wall of the jacket is a heat exchanger in which there is circulated a refrigerant fluid derived from the air conditioner installed in the vehicle. The heat exchanger acts to cool the battery to maintain the temperature of the electrolyte therein at a level at which the battery operates at optimal efficiency.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a national stage of International Application No. PCT/CN2008/001001, filed on May 22, 2008, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a process for preparing 4-acetyl-2,3,4,5-tetrahydro-benzo[1,4]diazepine and the intermediates thereof. More specifically, it relates to the compounds represented by formula I, II and IV, the processes for preparing the same, and their uses in the preparation of 4-acetyl-2,3,4,5-tetrahydro-benzo[1,4]diazepine.
BACKGROUND OF THE INVENTION
4-Acetyl-2,3,4,5-4H-benzo[1,4]diazepine (represented by formula A) is a pharmaceutical intermediate with biological activity, and has been applied in the preparation of tranquilization, antibiotic and anticancer drugs (J. Med. Chem. 1999, 42, 5241; J. Med. Chem. 1996, 39, 3539; Bioorg. Med. Chem. Lett., 2004, 14, 2603).
According to the literatures, in general, the compound represented by formula A is prepared by reducing 1,3,4-3H-benzo[1,4]diazepine-2,5-dione (represented by formula B) with LiAlH 4 to give a key intermediate represented by formula III, and then acetylating the compound represented by formula III, which is illustrated by reaction scheme 1. This process has disadvantages in that it needs high cost raw materials and is not suitable for a large-scale commercial production, because expensive LiAlH 4 was used in a very large amount in the reaction for preparing compound III from compound B, and anhydrous tetrahydrofuran which is difficult to be recovered was used as a solvent.
SUMMARY OF THE INVENTION
The inventors are directed to find a process for preparing 4-acetyl-2,3,4,5-4H-benzo[1,4]diazepine which is secure, simple, economic and suitable for large-scale commercial production, and thus the compounds represented by formula I, formula II and formula IV are invented and can be used to synthesize 4-acetyl-2,3,4,5-4H-benzo[1,4]diazepine in a facile and safe way.
Therefore, an object of the present invention is to provide the compounds represented by the formulae below, and another object of the present invention is to provide uses of these compounds for preparing 4-acetyl-2,3,4,5-4H-benzo[1,4]diazepine, an important pharmaceutical intermediate.
Hereinafter, the present invention will be described in detail.
The present invention provides a compound represented by formula I:
The present invention provides a process for preparing the compound represented by formula I, including condensing 2-nitrobenzaldehyde with 2-chloroethylamine hydrochloride in an organic solvent to yield the compound represented by formula I, as illustrated by reaction scheme 2:
In the above condensation reaction, the organic solvent is one selected from the group consisting of methanol, ethanol, propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 1-pentanol, 3-pentanol, ethyl acetate, ethylene glycol diethyl ether, ethylene glycol monomethyl ether, dichloromethane, 1,2-dichloroethane, toluene, xylene, DMF, DMSO, acetonitrile, tetrahydrofuran, dioxane and any mixture thereof.
The condensation reaction can be performed in the presence of water and a base selected from the group consisting of sodium methoxide, sodium ethoxide, sodium tert-butoxide, triethylamine, tri-n-butylamine, tripropylamine and pyridine.
The present invention provides a process for preparing a compound represented by formula II by using the compound represented by formula I,
including:
reducing the compound represented by formula I in the presence of a reducing agent to give the compound represented by formula II, as illustrated by reaction scheme 3:
wherein the reducing agent is one selected from the group consisting of NaBH 4 , KBH 4 and LiBH 4 .
The present invention also provides a process for preparing a compound represented by formula A by using the compound represented by formula I, including:
reducing the nitro group of the compound represented by formula I and cyclizing the compound in the presence of a reducing agent selected from the group consisting of Fe powder, Zn powder and SnCl 2 in an organic solvent to give a compound represented by formula V;
reducing the double bond of the compound represented by formula V in the presence of a reducing agent selected from the group consisting of NaBH 4 , KBH 4 and LiBH 4 to give a compound represented by formula III; and
then acetylating the compound represented by formula III with an acetylating agent selected from the group consisting of Ac 2 O and acetyl chloride to give the compound represented by formula A;
which is illustrated by reaction scheme 4:
The present invention provides a compound represented by the following formula II or its hydrochloride salt:
As mentioned above, the compound represented by formula II can be prepared by reducing the compound represented by formula I in the presence of a reducing agent. Its hydrochloride salt can be obtained by treating the compound represented by formula II with hydrochloride-ethanol.
The present invention provides a process for preparing a compound represented by formula A by using the compound represented by formula II,
including:
acetylating the compound represented by formula II with an acetylating agent selected from the group consisting of Ac 2 O and acetyl chloride in an organic solvent to give a compound represented by formula IV, and then reducing and cyclizing the compound represented by formula IV in the presence of a reducing agent selected from the group consisting of Fe powder, Zn powder and SnCl 2 in an organic solvent to give the compound represented by formula A, which is illustrated by reaction scheme 5:
or
reducing and cyclizing the compound represented by formula II in the presence of a reducing agent selected from the group consisting of Fe powder, Zn powder and SnCl 2 in an organic solvent to give the compound represented by formula III, and then acetylating the compound represented by formula III with an acetylating agent selected from the group consisting of Ac 2 O and acetyl chloride to give the compound represented by formula A, which is illustrated by reaction scheme 6:
or
reducing, cyclizing and acetylating simultaneously the compound represented by formula II in the presence of a reducing agent selected from the group consisting of Fe powder, Zn powder and SnCl 2 and an acetylating agent selected from the group consisting of Ac 2 O and acetyl chloride in an organic solvent to give the compound represented by formula A, as illustrated by reaction scheme 7:
The present invention also provides a process for preparing the compound represented by formula A from 2-nitrobenzaldehyde, including: in an organic solvent, after condensing 2-nitrobenzaldehyde with 2-chloroethylamine hydrochloride, performing nitro-reduction and cyclization reaction in the presence of a reducing agent selected from the group consisting of Fe powder, Zn powder and SnCl 2 , followed by a double bond-reduction in the presence of a reducing agent selected from the group consisting of NaBH 4 , KBH 4 and LiBH 4 to give the compound represented by formula III; and then acetylating the compound represented by formula III with an acetylating agent to give the compound represented by formula A, which is illustrated in reaction scheme 8:
In the acetylating reactions according to the present invention, for example, the reaction for acetylating the compound represented by formula III to give the compound represented by formula A and the reaction for acetylating the compound represented by formula II to give the compound represented by formula IV, and so on, the acetylating reactions are performed preferably in the presence of a base selected from the group consisting of sodium methoxide, sodium ethoxide, sodium tert-butoxide, triethylamine, tri-n-butylamine, tripropylamine and pyridine.
In the present invention, the used organic solvent is one selected from the group consisting of methanol, ethanol, propanol, isopropanol, 1-butanol, 2-butanol, tert-butanol, 1-pentanol, 3-pentanol, ethyl acetate, ethylene glycol diethyl ether, ethylene glycol monomethyl ether, dichloromethane, 1,2-dichloroethane, toluene, xylene, DMF, DMSO, acetonitrile, tetrahydrofuran, dioxane and any mixture thereof.
The present invention also provides a compound represented by formula IV:
The advantageous technical effects of the present invention are as follows. The present invention provides a novel process for preparing 4-acetyl-2,3,4,5-4H-benzo[1,4]diazepine, which is simple and easy-operated with easily available raw materials. The process according to the present invention is also economic and safe for the sake of avoiding the use of the expensive and unsafe LiAlH 4 .
DETAILED DESCRIPTION
Hereinafter, the technical solution of the present invention will be further illustrated by the Examples. The following examples are set forth to illustrate the invention more specifically, but are not to be construed to limit the technical solution of the present invention. All of the technical solutions of the present invention described above are those that can fulfill the aim of the present invention, that is, all of the reagents and temperatures used in the following examples can be interchanged with the corresponding reagents and temperatures described above to realize the objects of the present invention.
In the following examples, nuclear magnetic resonance (NMR) spectra were obtained on a Brucker AMX-400 NMR or Varian INVOA-600 NMR spectrometer with TMS as a IS, and the chemical shifts were reported in parts per million (ppm). Mass spectra were measured with a Finnigan MAT-95 or MAT-711 spectrometer. Silica gel with 200-300 mesh for column chromatography was purchased from Qingdao Ocean Chemical Co. Ltd. The silica gel plates for thin layer chromatography (TLC) were HSGF-254 preformed plates, which were commercially available from Yantai Huiyou Company, Yantai, China. The petroleum ether has a boiling point in the range of 60 to 90° C. The samples were monitored under UV-lamp and in iodine vapour. Unless stated otherwise in the examples, “concentrating” means that the solvents are distilled from the solution of the product by using a rotary evaporator, and “drying” indicates that the prepared compound is dried in a DHG-9240 thermostatic oven at 60° C.
EXAMPLE 1
Preparation of 2-chloro-N-(2-nitrobenzylidene)ethanamine (Compound Represented by Formula I, Referred to as Compound I Hereinafter)
2-nitrobenzaldehyde (20 g, 0.13 mol), 2-chloroethylamine hydrochloride (15 g, 0.14 mol), pyridine (8 ml, 0.13 mol) and toluene (150 ml) were mixed together, and the mixture was heated to be refluxed. After stirred for 3 hours, the reaction mixture was concentrated to give compound I (yield: 95%). 1 H NMR (300 MHz, CDCl 3 ): δ 3.85 (t, 2H, CH 2 ), 3.99 (t, 2H, CH 2 ), 7.60-8.02 (m, 4H, H on phenyl), 8.78 (s, 1H, CH).
EXAMPLE 2
Preparation of 2-chloro-N-(2-nitrobenzyl)ethanamine hydrochloride (Compound Represented by Formula II, Referred to as Compound II Hereinafter)
2-nitrobenzaldehyde (20 g, 0.13 mol), 2-chloroethylamine hydrochloride (15 g, 0.14 mol), MeOH (150 ml) were mixed together, and the mixture was stirred for 3 hours at room temperature. KBH 4 (3.4 g, 0.06 mol) was added into the reaction mixture in 4 portions (interval time: 10 minutes), and the stirring continued for 5 hours at room temperature. After the evaporation of some MeOH, the reaction mixture was adjusted to a pH of 9 to 10 with NaHCO 3 saturated solution, and extracted with dichloromethane. The resulting organic phase was washed with saturated brine, dried with anhydrous Na 2 SO 4 , and concentrated to give compound II as a white solid, which was then treated with hydrochloride-EtOH to give its hydrochloride salt (yield: 90%). 1 H NMR (300 MHz, DMSO): δ 3.45 (t, 2H, CH 2 ), 3.99 (t, 2H, CH 2 ), 4.51 (s, 2H, CH 2 ), 7.70-8.22 (m, 4H, H on phenyl).
EXAMPLE 3
Preparation of 2,3,4,5-tetrahydro-1H-benzo[e][1,4]diazepine (Compound Represented by Formula III, Referred to as Compound III Hereinafter)
Compound I (20 g, 0.1 mol) was dissolved in ethanol (150 ml), and Fe powder (11 g) was fed into the reaction mixture in 3 portions (interval time: 30 minutes). After stirred for 3 hours at 40-45° C., the reaction mixture was cooled, filtered to remove the Fe powder and insoluble solid. The filtered solid was washed with ethanol (50 ml), and the combined organic filtrate was added with K 2 CO 3 (69 g, 0.5 mol) under ice bath. After stirred for 30 minutes, the reaction mixture was treated with NaBH 4 g, 0.29 mol) in batches, stirred for another 30 minutes, filtered and concentrated. Dichloromethane (200 ml) and water (150 ml) were added into the resulting mixture, and the water phase was adjusted to a pH of 13 to 14 with NaOH (50% in water) and extracted with dichloromethane (150 ml×2). The combined organic phase was dried with anhydrous Na 2 SO 4 , concentrated to about 250 ml, and then treated with hydrochloride-isopropanol to give compound III in hydrochloride salt form (73 g, 65%). 1 H NMR (300 MHz, CDCl 3 ): δ 3.06 (m, 4H, 2CH 2 ), 3.92 (s, 2H, CH 2 ), 6.76-7.26 (m, 4H, H on phenyl).
EXAMPLE 4
Preparation of 2,3,4,5-tetrahydro-1H-benzo[e][1,4]diazepine (Compound III)
Compound II (21 g, 0.1 mol) was dissolved in ethanol (150 ml), and Fe powder (11 g) was fed into the reaction solution in 3 portions (interval time: 30 minutes). After stirred for 3 hours at 40-45° C., the reaction mixture was cooled and filtered to remove the Fe powder and insoluble solid. After concentrated, the filtrate was diluted with water (500 ml), and extracted with dichloromethane (3×50 ml). The water phase was adjusted to a pH of 9 to 10 with NaOH (1N) and extracted with dichloromethane again (3×100 ml). The combined organic phases were dried with anhydrous Na 2 SO 4 , filtered and concentrated to give compound III (yield: 70%).
EXAMPLE 5
Preparation of 2,3,4,5-tetrahydro-1H-benzo[e][1,4]diazepine (Compound III) Hydrochloride
2-nitrobenzaldehyde (75.5 g, 0.5 mol), 2-chloroethylamine hydrochloride (58 g, 0.5 mol), pyridine (40.3 ml, 0.5 mol) and ethanol (453 ml) were mixed together, and the mixture was stirred for 4 hours at room temperature. water (45 ml) and Fe powder (84 g, 1.5 mol) were then added thereinto, and the reaction mixture was refluxed for 2 hours. After cooled, the mixture was filtered and the filtered solid was washed with ethanol (50 ml). After the addition of K 2 CO 3 (69 g, 0.5 mol) under ice-bath, the combined filtrate was stirred for 30 minutes, and added by NaBH 4 (11 g, 0.29 mol). The stirring continued for another 30 minutes, and the reaction mixture was filtrated, concentrated, and added with dichloromethane (200 ml) and water (150 ml). The water phase was adjusted to a pH of 13 to 14 with NaOH (50% in water) and extracted with dichloromethane (150 ml×2). The combined organic phase was dried with anhydrous Na 2 SO 4 , concentrated to about 250 ml, and treated with hydrochloride-isopropanol to give the hydrochloride salt of compound III (66 g, yield: 60%).
EXAMPLE 6
Preparation of N-(2-chloroethyl)-N-(2-nitrobenzyl)acetamide (Compound Represented by Formula IV, Referred to as Compound IV Hereinafter)
Method 1: Under ice-bath cooling, compound II (21 g, 0.1 mol) was dissolved in dichloromethane (100 ml), and then added dropwise with acetyl chloride (10 ml). After the removal of the ice bath, the reaction mixture was stirred for 3 hours at room temperature, and poured into ice-water. The organic phase was separated, and concentrated to give compound IV (yield: 95%). 1 H NMR (300 MHz, CDCl 3 ): δ 2.09 (s, 3H, CH 3 ), 3.70 (m, 4H, 2CH 2 ), 4.97 (s, 2H, CH 2 ), 7.29-8.04 (m, 4H, H on phenyl).
Method 2: Under ice-bath cooling, compound II (21 g, 0.1 mol) was dissolved in dichloromethane (100 ml), Et 3 N (5 ml) was added thereinto, and then acetyl chloride (10 ml) was added dropwise. After the removal of the ice bath, the reaction mixture was stirred for 1.5 hours at room temperature, and poured into ice-water. The organic phase was separated, and concentrated to give compound IV (yield: 96%).
EXAMPLE 7
Preparation of the Compound Represented by Formula A (Referred to as Compound A Hereinafter)
Method 1: Under ice-bath cooling, compound III (14.8 g, 0.1 mol) was dissolved in dichloromethane (80 ml), Et 3 N (5 ml) was added thereinto, and then acetyl chloride (6 ml) was added dropwise. After the removal of the ice bath, the reaction mixture was stirred for 2 hours at room temperature, and poured into ice-water. The organic phase was separated, and concentrated to give a brown oily material, which was recrystallized in ethyl ether to give compound A (yield: 97%). 1 H NMR (300 MHz, DMSO): δ 1.95 and 2.02 (s+s, 3H), 3.05 and 3.09 (m, 2H, CH 2 ), 3.60 (m, 2H, CH 2 ), 4.58 and 4.64 (s+s, 2H, CH 2 ), 7.1-7.3 (m, 4H, H on phenyl). Mp 83.4-84.4° C.; MS (EI) m/z: 190 (M + ).
Method 2: Under ice-bath, compound III (14.8 g, 0.1 mol) was dissolved in dichloromethane (80 ml), and acetyl chloride (6 ml) was added dropwise thereinto. After the addition was finished, the ice bath was removed and the reaction mixture was continually stirred at room temperature for 5 hours. Then, the mixture was poured into ice-water, and the organic phase was separated and concentrated to give a brown oily material, which was recrystallized in acetone to give compound A (yield 96%).
EXAMPLE 8
Preparation of Compound A
Method 1: At room temperature, compound II (21 g, 0.1 mol) was dissolved in dichloromethane (150 ml), Et 3 N (5 ml) and Ac 2 O (10 ml) were added thereinto, and then Fe powder (11 g) was added in 3 portions (interval time: 30 minutes). The reaction mixture was heated and stirred for 8 hours at 40-45° C. After cooled, the reaction mixture was filtered to remove the Fe powder and insoluble solid. The filtrate was concentrated and diluted with water (500 ml). The resulting water phase was extracted with dichloromethane (3×50 ml), adjusted to a pH of 12 with NaOH (1N) and extracted with dichloromethane again (3×100 ml). The combined organic phases was dried with anhydrous Na 2 SO 4 , and concentrated to give a brown oily material, which was recrystallized in ethyl ether to give compound A (yield: 65%).
Method 2: At room temperature, compound II (21 g, 0.1 mol) was dissolved in dichloromethane (150 ml), Ac 2 O (10 ml) was added thereinto, and then Fe powder (11 g) was added in 3 portions (interval time: 30 minutes). The reaction mixture was heated and stirred for 18 hours at 40-45° C. After cooled, the reaction mixture was filtered to remove the Fe powder and insoluble solid, and the filtrate was concentrated and diluted with water (500 ml). The resulting water phase was extracted with dichloromethane (3×50 ml), adjusted to a pH of 12 with NaOH (1N), and extracted with dichloromethane again (3×100 ml). The combined organic phase was dried with anhydrous Na 2 SO 4 , and concentrated to give a brown oily material, which was recrystallized in acetone to give compound A (yield: 45%).
EXAMPLE 9
Preparation of Compound A
At room temperature, compound IV (25.6 g, 0.1 mol) was dissolved in dichloromethane (200 ml) at room temperature, and Fe powder (11 g) was added thereinto in 3 portions (interval time: 30 minutes). The reaction mixture was heated and stirred for 5 hours at 40-45° C. After cooled, the reaction mixture was filtered to remove the Fe powder and insoluble solid, and the filtrate was concentrated and diluted with water (500 ml). The resulting water phase was extracted with dichloromethane (3×50 ml), adjusted to a pH of 12 with NaOH (1N), and extracted with dichloromethane again (3×100 ml). The combined organic phase was dried with anhydrous Na 2 SO 4 , and concentrated to give a brown oily material, which was recrystallized in acetone to give compound A (yield: 70%).
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The present invention relates to a process for preparing 4-acetyl-2,3,4,5-tetrahydro-benzo[1,4]diazepine and the intermediates thereof. The present invention provides a compound represented by formula I and a compound represented by formula II, and processes for preparing 4-acetyl-2,3,4,5-tetrahydro-benzo[1,4]diazepine by using the compound represented by formula I, the compound represented by formula II and o-nitrobenzaldehyde. The invention has the advantages of the shorter synthesis steps, easily available raw materials and simple operation. Moreover, the process is economic and safe by avoiding the use of expensive and dangerous lithium aluminum hydride.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of turbomachines; it relates to the damping of a blade made of composite and is aimed more especially at damping turbojet engine fan blades.
[0002] Blades, particularly fan blades but also low-pressure compressor blades, made of carbon fiber composite, are produced in different ways. According to one method of manufacture, a stack of unidirectional plies or woven prepregs is formed and placed in a mold, orienting the successive plies differently, before compacting and polymerizing in an autoclave. According to another method, woven dry fiber prepregs are prepared and stitched together or alternatively, a single three-dimensional woven fiber or filament preform is created and then impregnated with resin by injection molding in a closed mold. The blade is made as a single piece comprising the root and the vane. It has various protective features to enhance its thermomechanical strength. Hence, a metallic protection is attached to the leading edge or to the entire contour of the vane comprising the leading edge, the blade tip and the trailing edge, this for example being in the form of a titanium component bonded to the entire surface of the leading edge and to a forward portion of the exterior surfaces of the extrados and of the intrados. Likewise, the exterior face of the intrados is reinforced by fitting a protective film that may be made of a synthetic material, for example polyurethane, bonded directly to the intermediate component.
[0003] The invention is aimed at this type of blade that has protection at least along the leading edge. One example of manufacture is described in patent EP 1.777.063 in the name of the present applicant.
[0004] Flutter is a phenomenon involving coupling between the aerodynamics and the elastic characteristics of the blade creating unstable situations. Flutter manifests itself asynchronously. A distinction is drawn between subsonic flutter and supersonic flutter. A fan blade is chiefly affected by subsonic flutter.
[0005] Flutter is a phenomenon that is difficult to predict because of the complexity of the coupling between the aerodynamic and mechanical responses. Further, mechanical blade damping is also generally not very well understood. Finally, in the present-day design of a blading that is being subjected to increasingly high loading, flutter is a phenomenon that needs to be taken into consideration quite especially.
DESCRIPTION OF THE PRIOR ART
[0006] In fan blade design, a flutter margin is estimated which is a measure, at a given flow rate, of the distance between the line of flutter and the operating line. This value is generally established from a known reference (the nearest one) to which are added the calculated differences between this reference configuration and the new configuration. The criteria nowadays used for subsonic flutter on 1 F and 1 T modes and on zero diameter coupled modes are:
The Twist Bend coupling (TBC) which represents the ratio between the displacements in the torsion mode and in the bending mode. The higher the TBC parameter, the greater the risk of flutter. The reduced speed or Strouhal criterion which is given by the following formula:
[0009] VR=W/C×f×pi, where W is the relative speed, C is the chord of the blade at a given height and f is the frequency of the blade mode considered. This criterion represents the coherency between the vibrational frequency of the blading and the frequency of the unsteadiness of the flow along this blading.
[0010] There are other factors that may influence the flutter margin and these may sometimes be used when the phenomenon is encountered during testing: reducing the specific flow rate, reducing the number of blades or increasing the chord length, lubricating the blade roots, detuning.
[0011] It is an object of the invention to improve the harmonic response of the blade to asynchronous aerodynamic excitations of the flutter type such as described hereinabove by substantially improving the mechanical damping of the blade.
[0012] Another object of the invention is to improve the harmonic response of the blade to synchronous aerodynamic excitations such as:
Inlet duct distortions caused by flying conditions involving an angle of incidence—in climbs, descents, crosswinds. Harmonic excitations generated by residual imbalance, Fed back pressure fluctuations caused by a fixed impeller of the flow straightener type on a fan impeller. Fed back pressure fluctuations or wake caused by a moving fan impeller on its neighbor in designs involving two contrarotating rotors.
[0017] The present applicant has, for a number of years, been investigating a damping technique performing initial evaluations on integrally bladed disks, or “blisks”. These terms denote a disk and blade assembly manufactured as a single piece. The principle of operation of the damping system relies on the dissipation of energy through the shearing of a suitably sited viscoelastic material. Correct behavior of the damping system is dependent on the dimensions of the material and good adhesion between the material and the engine component.
[0018] U.S. Pat. No. 6,471,484 is also known and describes a system for damping vibrations in a gas turbine engine rotor comprising an integrally bladed disk. The vanes of the blades are provided with a cavity hollowed in an intrados or extrados and containing a layer of a damping material with a stress layer. A cover sheet covers the cavity. In operation, vibration damping is encouraged by the shear stresses induced in the damping material between the vane and the stress layer, on the one hand, and within the damping material situated between the stress layer and the cover sheet, on the other hand.
SUMMARY OF THE INVENTION
[0019] The present invention aims to improve on this technique in an application to a blade made of composite with a means of protecting its leading edge.
[0020] According to the invention, the blade made of composite, comprising a vane formed of filaments or fibers impregnated with a thermosetting resin with a protective element in the region of the leading edge of the vane comprising a part, in the form of a rigid strip, said strip being secured to the vane, is one wherein at least one layer of a viscoelastic material is at least partially interposed between said rigid strip and the vane so as to form, with the protective element, a means of damping the vibrations of the vane.
[0021] The viscoelastic material is preferably taken from the following materials: rubber, silicone, elastomer polymer, for the low temperatures experienced on the fan, or epoxy resin.
[0022] The invention therefore consists in using a viscoelastic material for a blade such as a fan blade made of woven composite of the RTM type. This layer is located between the titanium leading edge and the woven composite vane as a full or partial replacement for the layer of adhesive currently used.
[0023] A mechanical damping function is introduced into the turbomachine blade, such as an RTM composite fan blade. This function is also beneficial in the event of accidental loadings such as bird strike (or the loss of a blade) as it helps to dissipate the impact energy. In the latter instance, it therefore performs a dual function of damping vibrational response and bird strike.
[0024] By using the leading edge coated with a protective device, particularly one made of titanium, as backing layer for the damping system, no additional components are introduced.
[0025] Thus, the solution of the invention combines a number of advantages:
Good integration of the composite blade. By using the metal leading edges as the backing layer, the additional cost of this damping function is limited. The functions of damping foreign-object damage and flutter are combined. There is leverage on the engineering, positioning and size of the damping zones.
[0030] The space left between the composite and the leading edge is suited to the necessary thickness of viscoelastic material. Thus, the layer of viscoelastic material is, for example, at least partially contained in a cavity formed in the composite or alternatively is at least partially contained in a cavity formed in the protective element.
[0031] The functions of this layer of viscoelastic material are:
To introduce mechanical damping for vibrational responses of the blade, particularly in the case of a fan blade in respect of bending mode 1 F and torsion mode 1 T. To play a part in damping during phenomena such as bird strike, by absorbing some of the impact energy and thus limiting blade damage.
[0034] Thus, depending on the envisioned damping, the layer of viscoelastic material extends under the strip over part of its surface, more specifically the layer of viscoelastic material extends over a zone corresponding to a zone of maximum deformation for a determined vibration mode of the blade. If appropriate, the layer of viscoelastic material extends over a zone running parallel to the leading edge of the vane and can cover the entire leading edge.
[0035] The damping material may be single layer or multilayer depending on the environment, on the materials used, and on the damping characteristics sought.
[0036] According to one particular embodiment, the protective element that protects the leading edge is V-shaped comprising a solid central part and two strips positioned one on each side. The solid part of the protective element covers the leading edge, and the strips partially cover the two, intrados and extrados, faces of the leading edge.
[0037] The protective element that protects the leading edge is advantageously made of a metal foil, particularly a titanium foil.
[0038] According to one embodiment, an additional rigid plate is inserted between said strip and the vane with two layers of viscoelastic material, one on each side of the plate. The layers of viscoelastic material on each side of the plate may differ.
[0039] The layer of viscoelastic material will have, for example, been secured to the strip and/or to the vane by hot-cementing a film of viscoelastic material, for example, a vulcanized elastomer, or alternatively the layer of viscoelastic material will have been secured to the strip and/or to the vane by bonding using an adhesive substance, and the latter preferably has a greater stiffness than the viscoelastic material.
[0040] The invention applies to gas turbine engine compressors and preferably to turbojet engine fans, possibly of the unducted fan type, in which the engine operating temperature is compatible with the operating temperature of the viscoelastic material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] One nonlimiting embodiment of the invention is now described in greater detail with reference to the attached drawings in which:
[0042] FIG. 1 schematically depicts a turbojet engine with a front-mounted fan.
[0043] FIG. 2 shows a composite fan blade with a protective element protecting the leading edge, and shows the zones that comprise a viscoelastic damper.
[0044] FIG. 3 shows, in a view of FIG. 2 from above, the region of the leading edge of the blade.
[0045] FIG. 4 shows a section on IV-IV of a first embodiment of how the viscoelastic material is arranged.
[0046] FIG. 5 shows another arrangement of the layer of viscoelastic material.
[0047] FIG. 6 shows another arrangement of the layer of viscoelastic material.
[0048] FIG. 7 shows another positioning of the damping means.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0049] FIG. 1 schematically depicts one example of a turbomachine in the form of a twin spool bypass turbojet engine 1 . A fan 2 on the front supplies the engine with air. The air compressed by the fan is split into two concentric flows F 1 and F 2 . The secondary, or bypass, flow F 2 is discharged directly into the atmosphere and provides an essential proportion of the motive thrust. The primary flow F 1 is guided through several compression stages 3 to the combustion chamber 4 where it is mixed with fuel and burnt. The hot gases power the various turbine stages 5 which drive the fan 2 and the compression rotors 3 . The gases are then discharged into the atmosphere.
[0050] FIGS. 2 and 3 show a fan blade 10 that can be used on this type of engine. This is a blade made of composite. In general, the composite part 10 A of the blade consists of fibers or filaments held together by a thermosetting resin. The fibers or filaments are made of carbon or some other material such as glass, silica, silicon carbide, alumina, aramid or an aromatic polyamide. The leading edge is covered with a metallic protection 10 B. In this instance, it is a titanium foil bonded via the layer 30 on to the composite which runs along the leading edge, with a strip forming a wing on each side: one wing 10 Bi on the intrados downstream of the leading edge and one wing 10 Be on the extrados downstream of the leading edge. The two wings are connected along the leading edge by a thicker part 10 B 2 . A blade such as this is manufactured, for example, using the technique described in patent EP 1.777.063 in the name of the current applicant.
[0051] According to this technique, a three-dimensional woven filament preform is constructed. The one-piece woven preform is then trimmed to shape by cutting around the contour in accordance with a three-dimensional chart. The component is placed in a forming mold. Next, after appropriate deformation, the component is placed in a compacting mold which makes the deformed preform more rigid. The leading edge is overcompacted so as to allow the protective element to be fitted along the leading edge. This is an element in the form of a longitudinal half-sleeve with two wings intended to cover a portion of the extrados and intrados walls downstream of the leading edge. As explained in the aforementioned patent, the protective element is placed in a mounting device capable of parting the wings. The protective element is positioned, via its leading edge pre-coated with adhesive, between the two wings then these wings are released.
[0052] The whole is placed in an injection mold into which there is injected a binder containing a thermosetting resin so as to impregnate the entire preform. Finally, the mold is heated.
[0053] According to the invention, at least one layer 20 of a viscoelastic material is incorporated between the vane 10 A and the protective element 10 B. The metal protective element 10 B forms a rigid backing layer for the vibration-damping system that it forms with the layer of viscoelastic material.
[0054] Viscoelasticity is a property of a solid or of a liquid which, when deformed, exhibits both viscous and elastic behavior by simultaneously dissipating and storing mechanical energy.
[0055] A rigid material in the vibration damping system is more rigid than the viscoelastic material of the layer. In other words, the isotropic or anisotropic elasticity characteristics of the material of the backing layer are greater than the isotropic or anisotropic characteristics of the viscoelastic material in the desired thermal and frequency operating range. By way of nonlimiting example, the material of the backing layer is a metal and the material of the viscoelastic layer is of the rubber, silicone, elastomer polymer, epoxy resin, type.
[0056] FIG. 2 depicts three different damping means 11 , 12 and 13 on three different zones incorporating at least one layer 20 of viscoelastic material under the protective element 10 B that protects the leading edge.
[0057] FIG. 4 shows, in section on IV-IV of FIG. 2 , the arrangement of the viscoelastic layer 20 between the foil of the protective element 10 B and the composite of the vane 10 A. The damping means 11 , 12 or 13 is placed in the zones where the amplitude of the dynamic deformations is preferably at its maximum, in this instance in that part of the vane that lies a remote distance from the root of the blade. This means may adopt various forms, oval or polygonal, dimensions and arrangements depending on the damping desired.
[0058] The viscoelastic material is made to stick to the vane by hot-cementing or alternatively by the interposition of a layer of adhesive 31 or, respectively, 32 , as depicted in FIG. 6 . In an alternative form, the stress layer that the foil forms is not stuck to the viscoelastic layer but pressed against it, being connected instead to the composite of the vane.
[0059] It should be noted that, in the zones outside of the damping means, the thickness of the viscoelastic layer is compensated for by the thickness of the layer of adhesive 30 that connects the foil to the composite.
[0060] According to an alternative form that has not been depicted, a cavity that forms a housing is machined, for the damper, in the foil, in the composite or in both.
[0061] FIG. 5 shows another alternative form of embodiment of the damper according to the invention. In this instance it consists of an additional stress sheet 40 , for example in the form of a metal sheet. A layer of viscoelastic material 21 is inserted between the foil of the protective element 10 B and the metal sheet 40 . A layer of viscoelastic material 22 , the same as 21 or different, is inserted between the stress sheet 40 and the surface of the vane 10 A. In this embodiment again, the layers may be joined together by hot-cementing or bonding depending on the materials selected.
[0062] FIG. 7 shows an alternative arrangement 14 of the damping system, the viscoelastic layer extending over a portion that is elongate along the leading edge of the vane 10 A.
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The present invention relates to a blade made of composite, comprising a vane formed of woven filaments impregnated with a thermosetting resin with a protective element in the region of the leading edge of the vane comprising a part in the form of a rigid strip, said strip being secured to the vane. The blade is characterized in that at least one layer of a viscoelastic material is at least partially interposed between said rigid strip and the vane so as to form, with the protective element, a means of damping the vibrations of the vane.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to a housing for an implantable stimulator, such as an implantable pacemaker, with at least one electrode connector for electrically and mechanically connecting the internal components of the stimulator to an electrode lead.
2. Description of the Prior Art
Implantable stimulators, such as a pacemaker, have a housing (also known as a “can”) which contains electronic circuitry and a power source (battery). The stimulator delivers stimulation energy, usually in the form of pulses, in vivo to tissue, such as cardiac tissue, via electrodes which are implanted so as to be in contact with the tissue. One or more electrode leads connect the stimulator to these electrodes. The leads must be mechanically and electrically connected to the housing. A single lead having multiple conductors, leading to respectively different electrodes, can be employed, or multiple leads can be used.
The internal components contained in the housing must be protected against the surrounding environment, especially body fluids, over a relatively long period of time. This requirement imposes high demands on all possible entry paths into the interior of the housing, and particularly on the connections of the leads to the housing. A fluid-type connection must be made between the lead or leads and the housing, but the connection must also afford the possibility to disconnect the stimulator housing from the implanted leads for replacement or servicing of the stimulator.
The connective parts of the stimulator and the leads have been substantially standardized in the pacing field, and generally a relatively deep female socket is used at the stimulator housing, which has a number of contact surfaces, and the lead or leads have a male portion carrying one or more corresponding, peripherally disposed, generally circular, contact surfaces.
Conventionally, the socket portion of the connection is made of a transparent material, usually epoxy resin, which is molded onto the stimulator housing, encompassing contacts which extend outwardly from the housing. The male portion of the lead is normally locked in this socket by set screws, although many other fastening arrangements are known in the art. The positioning and alignment of the different contact surfaces, and the positioning and alignment of the metallic threads for the set screws, prior to the molding of the female portion of the connector is relatively complicated, and there is also an unavoidable delay in the manufacturing process which arises due to the time needed for the epoxy resin to cure.
Moreover, since the connector is disposed at the top of the stimulator housing, the two halves of the housing which are joined together, after the circuit, power source and other components have been mounted therein, must necessarily be non-identical, and are usually mirror-symmetric. This requires that two differently shaped housing halves be manufactured and maintained in inventory.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a connector for an implantable stimulator device which can be assembled in the stimulator housing without the necessity of a molding procedure, which still providing the necessary fluid-tight mechanical and electrical connection of the electrode lead to the components contained in the stimulator housing.
The above object is achieved in accordance with the principles of the present invention in a connector for an electrode lead which is completely self-contained in an exterior tube, and which can be assembled, as a tubular unit, using two identical housing halves.
The entire assembly is prefabricated with an exterior tube, and it is then only necessary to weld the tube into or onto one of the housing halves. When two such prefabricated tubes are employed, the housing halves can be identical, and there is no need to separately manufacture, and maintain in inventory, two different, mirror-symmetrical, housing halves, as is necessary with conventional molded connections.
The electrical connection between the prefabricated tube and the hybrid substrate in the stimulator housing can be made directly, without the need for feed-throughs, by allowing the edge of the substrate to extend into a slot in the exterior tube, with the substrate being bonded thereto by welding, brazing or gluing. The substrate edge can be provided with contacts which may directly contact the contact pin of the lead, or can produce an electrical contact with the lead via an adapter. The two prefabricated tubes can then be attached to the substrate in advance so as to form a unit, and the entire unit then being placed in one housing half of the stimulator and connected to the battery, after which the other housing half is welded onto the first half. This is a considerable simplification over conventional procedures, wherein thin wires must be bonded to the feed-through block and to the substrate after mounting of the parts.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the internal components of an embodiment of a tube connector for use in the inventive stimulator.
FIG. 2 is a side view of a weld protector for the internal components shown in FIG. 1 .
FIG. 3 shows a titanium sleeve at the left part of the figure, which is slid onto the components in FIG. 1 covered by the weld protector of FIG. 2, to result in the assembly shown at the right part of the figure.
FIG. 4 shows the completed tubular connector in accordance with the invention.
FIG. 5 is a side sectional view of a more detailed embodiment of the tubular connector in accordance with the invention.
FIG. 6 shows a stimulator in accordance with the invention with two tubular connectors, in assembled form.
FIG. 7 shows the stimulator of FIG. 6 with the upper half of the stimulator removed.
FIG. 8 shows another embodiment of a stimulator in accordance with the invention employing tubular connectors, in assembled form.
FIG. 9 shows the stimulator of FIG. 8 with the top housing half removed.
FIG. 10 shows a stimulator employing a tubular connector in accordance with the invention in a further embodiment using a conventionally-shaped housing, with the top housing half removed.
FIG. 11 shows the stimulator of FIG. 10 in completely assembled form.
FIG. 12 is a sectional view of a further embodiment of a tubular connector in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The internal components of a tubular connector in accordance with the invention are schematically shown in highly simplified form in FIG. 1 . These components include an interior tube 1 and a feed-through block 2 , with conductors 3 and 4 proceeding through the feed-through block 2 and being electrically and mechanically connected to the interior tube one. FIG. 2 shows a weld protection sleeve 5 , having a longitudinal slot 6 therein, in which the components shown in FIG. 1 are contained so as to be protected against subsequent welding. FIG. 3, at the left, shows a titanium sleeve, also having a longitudinal slot 8 therein, which is slid over and welded to the sleeve 5 shown in FIG. 2, resulting in the assembly shown at the right of FIG. 3 . The slots 6 and 8 coincide in the assembly shown at the right of FIG. 3 .
In the finished tubular connector shown in FIG. 4, a viewing window 9 and a locking device 10 are molded in the coinciding slots 6 and 8 with transparent material. The assembly shown in FIG. 4 is thus a self-contained tubular connector which can be embodied, without further molding procedures, in a stimulator housing. Several examples of the simplified manner of assembling such a stimulator are shown in FIGS. 6 through 11.
In the embodiment shown in FIG. 6, a housing 11 has two slightly enlarged regions 12 and 13 at opposite sides thereof, which respectively receive the tube connectors 7 , as shown in FIG. 7 . The tubular connectors 7 are respectively connected to electrode leads 14 and 15 . FIG. 6 shows the housing 11 in completely assembled form, with a top housing half being welded or otherwise joined to a bottom housing half 16 , which is visible in FIG. 7 with the top half removed. As can be seen in FIG. 7, before the top housing half is joined to the bottom housing half 16 , a hybrid circuit 17 and a battery 18 are positioned, together with the tubular connectors, in the bottom housing half 16 . The top housing half then only needs to be fitted over these components, enjoined to the bottom housing half 16 . Moreover, as can be seen in FIGS. 6 and 7, the top and bottom housing halves are identical, i.e., they are not mirror-symmetrical as in a conventional pacemaker housing. Therefore, only one housing half shape needs to be manufactured and maintained in inventory, thereby considerably simplifying manufacturing and assembly.
Another embodiment wherein identical housing halves can be employed is shown in FIGS. 8 and 9. In this embodiment, the assembled housing 19 shown in FIG. 8 has two enlarged side portions 20 and 21 from which electrode leads 22 and 23 respectively extend. As can be seen in FIG. 9, wherein the top half of the housing has been removed so as to expose the bottom housing half 24 , tubular connectors 7 are again mounted at opposite sides of the housing, and a hybrid 17 and a battery 18 are positioned therein. Again, the top housing half only needs to be joined to the bottom housing half with all components mounted therein as shown in FIG. 9 .
If more electrodes are needed, it would also be possible to arrange two further electrodes in the embodiment shown in FIGS. 8 and 9 at the unoccupied housing regions, generally forming a square in combination with the illustrated electrode leads.
The embodiment shown in FIGS. 10 and 11 makes use of a conventionally shaped pacemaker housing having mirror-symmetric housing halves, and thus the advantage of being able to manufacture and maintain a single housing half shape does not apply to the embodiment of FIGS. 10 and 11, but the overall assembly using the self-contained connector tube 7 is still applicable. FIG. 10 shows a conventional posterior housing half 25 , with the tubular connector 7 and the hybrid 17 and the battery 18 mounted therein, electrically connected by lead wires. FIG. 11 shows the completely assembled stimulator, with the front half 26 of the housing welded in place, not only to the posterior housing half 25 , but also to the tubular connector 7 , by means of weld seam 27 .
FIG. 5 is a sectional view of one embodiment of a tubular connector 29 , shown mounted in a housing 28 with a lead 30 inserted therein. The housing 28 contains a hybrid circuit 31 , to which the tubular connector 29 is electrically connected by wires 32 and 33 , which are appropriately bonded to the hybrid circuit 31 , and which proceed through openings in the outer sleeve 34 of the tubular connector 29 . As can be seen in FIG. 5, the opposite ends of the outer sleeve 34 of the tubular connector 29 have annular channels therein, so that the tubular connector 29 is held in place by the housing 28 .
From one end of the tube 34 (the left side in FIG. 5 ), a ceramic plug 42 is inserted, in which contact rings 38 and 39 have been molded. The ceramic plug 42 has a central bore therein which is shaped to accommodate the lead 30 . The ceramic plug 42 has an annular channel in which a circular spring contact 40 is inserted, in mechanical and electrical contact with the contact 39 . The contact 38 projects beyond the inner terminating end of the plug 42 , and thus an open annular channel is present at that end of the plug 42 , which receives another circular spring contact 40 , in electrical and mechanical contact with the contact 38 . This open end of the plug 42 is closed by a cylindrical component 36 , which is inserted through the other end (the right end in FIG. 5) of the sleeve 34 . The plug 36 has a central bore therein, which may be provided with threads. A resilient locking ring 37 is inserted into the bottom of this bore, and the bore is closed by a plug 35 which is screwed into the threads in the bore of the plug 36 .
The lead 30 carries four sealing rings 43 , 44 , 45 and 46 . The lead 30 has a first contact surface 47 which, when the lead 30 is inserted in the opening in the tubular connector 29 , makes electrical contact with the contact 41 , to produce an electrical path to the hybrid circuit 31 via the contact 41 , the contact 39 and the wire 32 . The lead 30 also has a second contact surface 48 which, when the lead 30 is inserted in the tubular connector 29 , makes electrical contact with the contact 40 , thereby producing an electrical path to the hybrid circuit 31 via the contact 40 , the contact 38 and the wire 33 .
Another embodiment is shown in FIG. 12, wherein a substrate 53 of ceramic material is mounted in a slot 52 of an exterior tube 50 of the tubular connector 49 . The substrate 53 is for the purpose of making electrical connections to the circuitry within the stimulator housing. The exterior tube 50 has a cylindrical bore 51 therein, which receives an end of an electrode lead 57 in a tubular adapter 61 . The tubular adapter 61 has a flanged end 55 , one side 54 of which is hinged so as to be openable to allow the lead 57 to be inserted therein, and can be provided with annular ribs so that when it is closed, as shown in FIG. 12, the lead 57 is firmly held therein. The lead 57 has sealing rings and contact surfaces as described in connection with the embodiment of FIG. 5 . O-rings 56 , 59 and 60 are provided for sealing purposes. Contacts 53 a (which are not visible in the sectional plane shown in FIG. 12 and which are therefore schematically indicated by dashed lines) provide an electrical path between the lead 57 and the substrate 53 .
Although modifications and changes may be suggested by those skilled in the art, it is the intention of the inventors to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of their contribution to the art.
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An implantable heart stimulator has a connector for an electrode lead in the form of a self-contained tubular connector, which can be placed as a unit in one-half shell of a stimulator housing, together with a hybrid circuit and a power source. The other half shell of the stimulator housing can then simply be placed over these assembled components and joined thereto by welding, thereby considerably simplifying manufacture and assembly of the stimulator. When an even number of such self-contained connector tubes is employed, the two stimulator housing half shells can be identical.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bit line sense-amplifier for a semiconductor memory device more particularly to a method for driving a bit line sense-amplifier for a semiconductor memory device which does not apply a bit line precharge voltage by using a switching means in an equalization operation, performs an equalization operation by interconnecting sense-amplifier lines, then performs a precharge operation by applying a bit line precharge voltage through NMOS transistor of the switching means, increases a sensing speed by reducing a loading of a sense-amplifier, decreases a transient current, and minimizes a power-consumption by performing a precharge operation after a bit line equalization.
2. Description of the Prior Art
FIG. 1 is a circuit diagram of a conventional bit line sense-amplifier.
Referring to FIG. 1, the conventional bit line sense-amplifier as of a folded bit line structure includes: a unit cell 1 which is connected between a first bit line BITH and a cell plate voltage terminal VCP, and is comprised of a first NMOS. transistor MN 1 and a cell capacitance C 1 ; a first line connector 2 which is comprised of second and third. NMOS transistors (MN 2 , MN 3 ), and achieves a connection or a cut-off between first bit lines (BITH, /BITH) and sense-amplifier lines (SA, /SA) by using a first bit line cut-off signal BISH; a second line connector 3 which is comprised of 10th and 11th NMOS transistors (MN 10 , MN 11 ), and achieves a connection or a cut-off between second bit lines (BITL, /BITL) and sense-amplifier lines (SA , /SA) by using a second bit line cut-off signal BISL; a sense-amplifier 5 which is comprised of first and second PMOS transistors (MP 1 , MP 2 ) and 8th and 9th NMOS transistors (MN 8 , MN 9 ), is connected sense-amplifier lines (SA, /SA), is driven by sense-amplifier control signals (RTO, /S), and performs a bit line sensing operation; and a data bus line connector 6 which is comprised of 12th and 13th NMOS transistors (MN 12 , MN 13 ), is operated by a column selection signal YI_SEL, and achieves a connection or a cut-off between sense-amplifier lines (SA, /SA) and data bus lines (DB, /DB).
A bit line sensing operation of the conventional bit line sense-amplifier shown in FIG. 1 will be described with reference to FIGS. 2-3.
FIG. 2 is a circuit diagram showing a driving method of the conventional bit line sense-amplifier shown in FIG. 1, and FIG. 3 is a timing diagram of the conventional bit line sense-amplifier shown in FIG. 1 .
As to a bit line sense-amplifier in an initial state as shown in FIG. 2 ( a ), since the first and second bit line cut-off signals (BISH, BISL) are at a high level state as shown in FIGS. 3 ( a )- 3 ( b ), the first and second bit lines (BITH, /BITH, BITL, /BITL) are connected to the sense-amplifier lines (SA, /SA). Also, a bit line precharge voltage VBLP being a half Vcc power generator is applied to the above lines as shown in FIGS. 3 ( c ), 3 ( h ) and 3 ( i ).
Then, as shown in FIG. 2 ( b ), the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA) by the second bit line cut-off signal BISL.
That is, as shown in FIGS. 3 ( b )- 3 ( c ), if the second bit line cut-off signal BISL and a bit line equalization signal BLP are changed from a high level state to a low level state, the fifth, sixth and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising a bit line equalization unit 4 and the 10th and 11th NMOS transistors (MN 10 , MN 11 ) comprising the second line connector 3 , thereby separating the second bit lines (BITL, /BITL) from the sense-amplifier lines (SA, /SA).
Then, a word line WL is selected as shown in FIG. 3 ( d ), a voltage division occurs in the first bit line BITH shown in FIG. 2 ( c ) and the sense-amplifier line SA shown in FIGS. 3 ( h ) and 3 ( i ).
After that, a sensing operation and a write-back operation to a storage node STR inside of the unit cell 1 are performed in the sense-amplifier 5 .
That is, sense-amplifier control signals (RTO, /S) are applied as shown in FIGS. 3 ( f ) and 3 ( g ) so that an amplified signal is applied to the sense-amplifier lines (SA, /SA). As shown in FIG. 2 ( d ), the amplified signal is write-back processed to a storage node inside of the unit cell 1 .
In this course, the sense-amplifier lines (SA, /SA) and the first bit lines (BITH, /BITH) are interconnected so that a power-consumption occurs according to a loading of the first bit lines (BITH, /BITH). Here, the second and third NMOS transistors comprising the first line connector 2 are turned on because the first bit line cut-off signal BISH is at a high level state, so that the upper bit line is connected to the sense-amplifier lines.
Then, an equalization operation and a precharge operation of the first and second bit lines (BITH, /BITH, BITL, /BITL) and the sense-amplifier lines (SA, /SA) are performed at the same time.
Namely, as shown in FIGS. 3 ( d ), 3 ( f ) and 3 ( g ), a word line WL is changed from a high level state to a low level state, and the sense-amplifier control signals (RTO, /S) are disabled with a half Vcc level. As shown in FIGS. 3 ( b ) and 3 ( c ), the second bit line cut-off signal BISL and a bit line equalization signal BLP are changed from a low level state to a high level state, so that the signals BISL and BLP are enabled. As shown in FIG. 2 ( e ), the first and second bit lines (BITH, /BITH, BITL, /BITL) and the sense-amplifier lines (SA, /SA) are equalized and precharged.
In this course, since the equalization operation and the precharge operation are performed at the same time, a voltage of one sense-amplifier line SA between two sense-amplifier lines (SA, /SA) is amplified as a first Vcc voltage as shown in FIG. 3 ( h ) by a sensing operation, and a voltage of the other sense-amplifier line (/SA) drops to a ground level voltage Vss, thereby occurring a power-consumption in a precharging process.
Accordingly, unnecessary power-consumption generated in a conventional sensing and precharging process should be removed, and increasing a sensing speed should minimize a current consumption in a chip operation.
To solve this problem, there is provided three kinds of methods in the present invention.
SUMMARY OF THE INVENTION
Accordingly, the present invention is that directed to a bit line sense-amplifier for a semiconductor memory device and a method for driving the same that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
It is an objective of the present invention to provide a it line sense-amplifier for a semiconductor memory device and a method for driving the same, which prevent a power-consumption by performing a precharge operation after an equalization operation in a precharge operation.
To achieve the above objective, a bit line sense-amplifier for a semiconductor memory device includes: first and second bit lines respectively having two bit lines, for transmitting a stored data to a memory cell; sense-amplifier lines for transmitting a data loaded on the first bit line to a sense-amplifier; first and second switches which are controlled by first and second control signals, and selectively connect two bit lines of the first bit line to the sense-amplifier lines; third and fourth switches which are controlled by third and fourth control signals, and selectively connect two bit lines of the second bit line to the sense-amplifier lines; and a fifth switch which is controlled by a fifth control signal, and selectively applies a bit line precharge voltage to the sense-amplifier lines.
A method for driving a bit line sense-amplifier includes the steps of: (a) interconnecting first and second bit lines and sense-amplifier lines, and applying a bit line precharge voltage to the sense-amplifier lines; (b) separating the second bit line from the sense-amplifier lines, and separating the sense-amplifier lines from the bit line precharge voltage; (c) selecting a desired memory cell, and transmitting a data to the bit lines and the sense-amplifier lines by a voltage division; (d) sensing a data transmitted to the sense-amplifier lines by a sense-amplifier, and performing a write-back operation to the selected memory cell; (e) performing an equalization by interconnecting the sense-amplifier lines; and (f) connecting the data lines with the sense-amplifier lines, and applying the bit line precharge voltage to the sense-amplifier lines.
Additional features and advantages of the invention will be set forth in the description, which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objective and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and other advantages of the present invention will become apparent from the following description in conjunction with the attached drawings, in which:
FIG. 1 is a circuit diagram of a conventional bit line sense-amplifier;
FIG. 2 is a circuit diagram showing a driving method of the conventional bit line sense-amplifier shown in FIG. 1;
FIG. 3 is. a timing diagram of the conventional bit line sense-amplifier shown in FIG. 1;
FIG. 4 is a circuit diagram of a bit line sense-amplifier according to the present invention;
FIG. 5 is a circuit diagram showing a driving method of the bit line sense-amplifier shown in FIG. 4 in accordance with a first method of the present invention;
FIG. 6 is a timing diagram of the bit line sense-amplifier shown in FIG. 4 in accordance with a first method of the present invention;
FIG. 7 is a circuit diagram showing a driving method of the bit line sense-amplifier shown in FIG. 4 in accordance with a second method of the present invention;
FIG. 8 is a timing diagram of the bit line sense-amplifier shown in FIG. 4 in accordance with a second method of the present invention;
FIG. 9 is a circuit diagram showing a driving method of the bit like sense-amplifier shown in FIG. 4 in accordance with a third method of the present invention;
FIG. 10 is a timing diagram of the bit line sense-amplifier shown in FIG. 4 in accordance with a third method of the present invention;
FIG. 11 shows a magnitude of a current measured at a ground terminal in the bit line sense-amplifier of the first method;
FIG. 12 shows a magnitude of a current measured at a ground terminal in the bit line sense-amplifier of the second method;
FIG. 13 shows a magnitude of a current measured at a ground terminal in the bit line sense-amplifier of the third method; and
FIG. 14 shows a magnitude of a current measured at a ground terminal in the bit line sense-amplifier of the conventional art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention will now be described in detail with reference to the accompanying drawings.
FIG. 4 is a circuit diagram of a bit line sense-amplifier according to the present invention.
A basic circuit configuration of the bit line sense-amplifier shown in FIG. 1 is the same as the conventional bit line sense-amplifier. An additional portion added to the circuit configuration of the conventional bit line sense-amplifier will be described below.
First, a bit line precharge unit 10 having NMOS transistor MN 4 controlled by a bit line precharge signal CON_VBLP is added between the conventional bit line precharge voltage terminal VBLP and the conventional bit line equalization unit 4 , so that a bit line equalization operation and a bit line precharge operation can be separately performed.
Also, the conventional bit line sense-amplifier simultaneously connects the first bit lines (BITH, /BITH) and the second bit lines (BITL, /BITL) to the sense-amplifier lines (SA, /SA) by making a first line connector 2 and a second line connector 3 . But, the present invention includes four line connectors ( 21 , 22 , 31 , 32 ), and makes NMOS transistors (MN 2 , MN 3 , MN 10 , MN 11 ) be respectively controlled.
That is, by a first line connector 21 , the first bit line BITH is connected to a sense-amplifier line SA, or is separated from the sense-amplifier line SA. And, by the second line connector 22 , another first bit line /BITH is connected to another sense-amplifier line /SA, or is separated from another sense-amplifier line /SA.
In addition, by a third line connector 31 , the second bit line BITL is connected to the sense-amplifier line SA, or is separated from the sense-amplifier line SA. And, by the fourth line connector 32 , another second bit line /BITL is connected to another sense-amplifier line /SA, or is separated from another sense-amplifier line /SA.
A process from a sensing operation to a precharge operation according to three kinds of methods (i.e., first method, second method, and third method) will now be described with reference to the accompanying drawings.
First, the first method will now be described with reference to FIGS. 4-6.
FIG. 5 is a circuit diagram showing a driving method of the bit line sense-amplifier shown in FIG. 4 in accordance with a first method of the present invention; and FIG. 6 is a timing diagram of the bit line sense-amplifier shown in FIG. 4 in accordance with a first method of the present invention.
The first method separately performs a bit line equalization operation and a precharge operation after a sensing operation, so that a precharge operation is performed after the equalization operation, thereby preventing a power-consumption generated in the precharge operation.
In an initial state as shown in FIG. 5 ( a ), the first and second bit line cut-off signals (BISH 1 , BISH 2 , BISL 1 , BISL 2 ) are at a high level state as shown in FIGS. 6 ( a )- 6 ( b ), so that the first and second bit lines (BITH, /BITH, BITL, /BITL) are connected to the sense-amplifier lines (SA, /SA). As shown in FIGS. 6 ( c )- 6 ( d ), since a bit line equalization signal BLP and the bit line precharge signal CON_VBLP are at a high level state, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising a bit line equalization unit 4 and a fourth NMOS transistor MN 4 comprising a bit line precharge unit 10 are turned on, a bit line precharge voltage VBLP being a half Vcc power generator is applied to the first and second bit lines (BITH, /BITH, BITL, /BITL) and the sense-amplifier lines (SA, /SA) as shown in FIGS. 6 ( i )- 6 ( j ).
After that, as shown in FIG. 5 ( b ), the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA) by the second bit line cut-off signals (BISL 1 , BISL 2 ).
As shown in FIGS. 6 ( b ) and 6 ( c ), if the second bit line cut-off signals (BISL 1 , BISL 2 ) and the bit line equalization signal BLP are changed from a high level state to a low level state, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising the bit line equalization unit 4 are turned off, the 10th NMOS transistor MN 10 comprising the third line connector 31 and the 11th NMOS transistor MN 11 comprising the fourth line connector 32 are turned off, and thus the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA).
As shown in FIG. 6 ( d ), since the bit line precharge signal CON_VBLP is changed from a high level state to a low level state, the fourth NMOS transistor MN 4 comprising the bit line precharge unit 10 is turned off, thereby a bit line precharge voltage VBLP is not applied to the sense-amplifier lines (SA, /SA).
Then, a word line WL is selected as shown in FIG. 6 ( e ), and a voltage division occurs in the first bit line BITH and the sense-amplifier line SA as shown in FIGS. 6 ( i )- 6 ( j ).
As shown in FIG. 5 ( d ), a sensing operation of the sense-amplifier and a write-back operation to the unit cell 1 are performed.
Namely, sense-amplifier control signals (RTO, /S) are applied as shown in FIGS. 6 ( g )- 6 ( h ), an amplified signal is then applied to the sense-amplifier lines (SA, /SA), and the amplified signal is write-back processed to the unit cell 1 .
Then, as shown in FIG. 5 ( e ), an equalization operation about the sense-amplifier lines (SA, /SA) and the first bit lines (BITH, /BITH) is performed by a bit line equalization signal BLP.
Namely, under the condition the word line WL is disabled as shown in FIG. 6 ( e ), if the bit line equalization signal BLP is enabled as shown in FIG. 6 ( c ), the fifth, sixth and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising the bit line equalization unit 4 are turned on, thereby performing an equalization operation.
Accordingly, as shown in FIGS. 6 ( i )- 6 ( j ), the first bit lines (BITH, /BITH) and the sense-amplifier lines (SA, /SA) have a half Vcc voltage according to a voltage division.
After that, as shown in FIG. 5 ( f ), a precharge operation is performed.
Namely, the 10th NMOS transistor MN 10 comprising the third line connector 31 and the 11th NMOS transistor MN 11 comprising the fourth line connector 21 are turned on by enabling second bit line cut-off signals (BISL 1 , BISL 2 ) as shown in FIG. 6 ( b ), thereby connecting the second bit lines (BITL, /BITL) to the sense-amplifier lines (SA, /SA). As shown in FIG. 6 ( d ), enabling the bit line precharge signal CON_VBLP performs a precharge operation.
Therefore, a bit line precharge voltage VBLP is applied under the condition the sense-amplifier lines (SA, /SA) and the first bit lines (BITH, /BITH) are at a half Vcc level, so that a power-consumption is not generated in a precharge process.
As described above, the first method performs a precharge operation after performing an equalization operation, thus solves a power-consumption problem generated when the equalization operation and the precharge operation are performed at the same time.
Next, the second method will now be described with reference to FIGS. 4, 7 , and 8 . A sensing operation and a precharge operation will be described with reference to FIGS. 4, 7 , and 8 .
FIG. 7 is a circuit diagram showing a driving method of the bit line sense-amplifier shown in FIG. 4 in accordance with a second method of the present invention; and FIG. 8 is a timing diagram of the bit line sense-amplifier shown in FIG. 4 in accordance with a second method of the present invention.
After completing a word line enable process, the second method separates the first line connector 21 and the second line connector 22 interconnecting the first bit lines (BITH, /BITH) and the sense-amplifier lines (SA, /SA) from the sense-amplifier lines (SA, /SA) through the first bit line cut-off signals (BISH 1 , BISH 2 ), and then performs a sensing operation.
A process from the initial state to a word line enable step in the second method is the same as the first method.
In an initial state as shown in FIG. 7 ( a ), the first and second bit line cut-off signals (BISH 1 , BISH 2 , BISL 1 , BISL 2 ) are at a high level state as shown in FIGS. 8 ( a ), 8 ( b ), 8 ( c ) and 8 ( d ), so that the first and second bit lines (BITH, /BITH, BITL, /BITL) are connected to the sense-amplifier lines (SA, /SA).
As shown in FIGS. 8 ( e )- 8 ( f ), since a bit line equalization signal BLP and the bit line precharge signal CON_VBLP are at a high level state, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising a bit line equalization unit 4 and a fourth NMOS transistor MN 4 comprising a bit line precharge unit 10 are turned on, a bit line precharge voltage VBLP being a half Vcc power generator is applied to the first and second bit lines (BITH, /BITH,BITL,/BITL) and the sense-amplifier lines (SA,/SA) as shown in FIGS. 8 ( k )- 8 ( l ).
After that, as shown in FIG. 7 ( b ), the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA) by the second bit line cut-off signals (BISL 1 , BISL 2 ).
As shown in FIGS. 8 ( c ), 8 ( d ) and 8 ( e ), if the second bit line cut-off signals (BISL 1 , BISL 2 ) and the bit line equalization signal BLP are changed from a high level state to a low level state, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising the bit line equalization unit 4 are turned off, the 10th NMOS transistor MN 10 comprising the third line connector 31 and the 11th NMOS transistor MN 11 comprising the fourth line connector 32 are turned off, and thus the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA).
As shown in FIG. 8 ( f ), since the bit line precharge signal CON_VBLP is changed from a high level state to a low level state, the fourth NMOS transistor MN 4 comprising the bit line precharge unit 10 is turned off, thereby a bit line precharge voltage VBLP is not applied to the sense-amplifier lines (SA, /SA) as shown in FIG. 7 ( b ).
After that, as shown in FIG. 7 ( c ), a word line WL is selected as shown in FIG. 8 ( g ), and a voltage division is performed to the first bit line BITH and the sense-amplifier line SA as shown in FIGS. 8 ( k )- 8 ( l ).
Next, as shown in FIG. 7 ( d ), since there is a voltage difference between the two sense-amplifier lines (SA, /SA) as shown in FIGS. 8 ( k )- 8 ( l ) because of a charge division, the first bit line cut-off signals (BISH 1 , BISH 2 ) are disabled as shown in FIGS. 8 ( a )- 8 ( b ), and the second NMOS transistor MN 2 comprising the first line connector 21 and the third NMOS transistor MN 3 comprising the second line connector 22 are turned off, thereby separating the first bit lines (BITH, /BITH) from the sense-amplifier lines (SA, /SA).
Then, as shown in FIG. 7 ( e ), sense-amplifier control signals (RTO, /S) are enabled as shown in FIGS. 8 ( i )- 8 ( j ), so that an amplified signal is applied to the sense-amplifier lines (SA, /SA).
In this course, a loading is lowered because the first bit lines (BITH, /BITH) are isolated from the sense-amplifier lines (SA, /SA), so that a sensing operation rapidly occurs and a transient current is decreased. In addition, a power line bouncing is decreased through a peak reduction of the transient current.
In the conventional bit line sense-amplifier structure, the first bit line /BITH is moved to a high or low level state according to a sense-amplifier operation, and is then moved to a half Vcc level. However, the present invention does not require this conventional operation by isolating the first bit line /BISH from the sense-amplifier line /SA.
After that, the second NMOS transistor MN 2 comprising the first line connector 21 is turned on by enabling the first bit line cut-off signal BISH 1 shown in FIG. 8 ( a ), so that the first bit line BITH is connected to the sense-amplifier line SA. At this time, a write-back operation to the unit cell 1 is performed as shown in FIG. 7 ( f ), and a potential level of the sense-amplifier line SA may be slightly lowered as shown in FIG. 8 ( k ).
In a folded bit line structure, another first bit line /BITH to which a cell is not connected is not changed at a half Vcc level when a voltage division occurs by an enabled word line. Also, since the cell is not connected to another first bit line /BITH, there is no need to perform a write-back operation.
Then, as shown in FIG. 7 ( g ), under the condition that the first bit line BITH is only connected to the sense-amplifier line SA, the sense-amplifier lines (SA, /SA) are mutually equalized.
Namely, the bit line equalization signal BLP shown in FIG. 8 ( e ) is enabled, and thus the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising the bit line equalization unit 4 are turned on, thereby interconnecting the sense-amplifier lines (SA, /SA).
In this case, the sense-amplifiers of 1K column are connected to another sense-amplifiers through NMOS transistor MN 5 being an equalization transistor in one bank. A probability that a cell is at a high or low level state is 50%. Accordingly, a percentage of a high or low level state of cells in one bank is shown as a Gaussian distribution centering around 50%. For example, assuming that a high level state of 50% and a low level state of 50% are accurately made, the sense-amplifier lines (SA, /SA) and the first bit line BITH are equalized with a half Vcc voltage.
Assuming that the high level state of 50% and the low level state of 50% are not made, the sense-amplifier lines (SA, /SA) and the first bit line BITH may be equalized with a voltage slightly deviated from the half Vcc voltage.
After that, as shown in FIG. 7 ( h ), a precharge operation is performed.
That is, the bit line cut-off signals (BISH 2 , BISL 1 , BISL 2 ) are enabled as shown in FIGS. 8 ( b ), 8 ( c ), and 8 ( d ), the third NMOS transistor MN 3 comprising the second line connector 22 , the tenth NMOS transistor MN 10 comprising the third line connector 23 , and the 11th NMOS transistor MN 11 comprising the fourth line connector 32 are turned on, so that the first bit line /BITH is connected to the sense-amplifier line /SA and the second bit lines (BITL, /BITL) are connected to the sense-amplifier lines (SA, /SA).
As shown in FIG. 8 ( f ), a bit line precharge signal CON_VBLP is enabled, the fourth NMOS transistor MN 4 comprising the bit line precharge unit 10 is turned on, so that a bit line precharge voltage VBLP is applied to the bit lines (BITH, /BITH, BITL, /BITL) and the sense-amplifier lines (SA, /SA).
If an equalization operation is performed with a voltage slightly deviated from a half Vcc voltage in an equalization process, a unit at which this equalization operation occurs is precharged with a half Vcc voltage by the bit line precharge voltage VBLP, thereby preventing a power-consumption.
As described above, the second method connects only a bit line connected to a cell selected in a write-back process to the sense-amplifier lines, thereby performing a half write-back operation.
Next, the third method will now be described with reference to FIGS. 4, 9 , and 10 . A process from an initial state to a sensing operation of a sense-amplifier in the third is the same as the second method. But, the third method performs a full write-back operation.
FIG. 9 is a circuit diagram showing a driving method of the bit line sense-amplifier shown in FIG. 4 in accordance with a third method of the present invention; and FIG. 10 is a timing diagram of the bit line sense-amplifier shown in FIG. 4 in accordance with a third method of the present invention.
In an initial state as shown in FIG. 9 ( a ), the first and second bit line cut-off signals (BISH 1 , BISH 2 , BISL 1 , BISL 2 ) are at a high level state as shown in FIGS. 10 ( a ), 10 ( b ), 10 ( c ) and 10 ( d ), so that the first and second bit lines (BITH, /BITH, BITL, /BITL) are connected to the sense-amplifier lines (SA, /SA).
As shown in FIGS. 10 ( e )- 10 ( f ), since a bit line equalization signal BLP and the bit line precharge signal CON_VBLP are at a high level state, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising a bit line equalization unit 4 and a fourth NMOS transistor MN 4 comprising a bit line precharge unit 10 are turned on, a bit line precharge voltage VBLP being a half Vcc power generator is applied to the first and second bit lines (BITH, /BITH, BITL, /BITL) and the sense-amplifier lines (SA, /SA) as shown in FIGS. 10 ( k )- 10 ( l ).
After that, as shown in FIG. 9 ( b ), the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA) by the bit line cut-off signals (BISL 1 , BISL 2 ).
As shown in FIGS. 10 ( c ), 10 ( d ) and 10 ( e ), if the bit line cut-off signals (BISL 1 , BISL 2 ) and the bit line equalization signal BLP are changed from a high level state to a low level state, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising the bit line equalization unit 4 are turned off, the 10th NMOS transistor MN 10 comprising the third line connector 31 and the 11th NMOS transistor MN 11 comprising the fourth line connector 32 are turned off, and thus the second bit lines (BITL, /BITL) are isolated from the sense-amplifier lines (SA, /SA).
As shown in FIG. 10 ( f ), since the bit line precharge signal CON_VBLP is changed from a high level state to a low level state, the fourth NMOS transistor MN 4 comprising the bit line precharge unit 10 is turned off, thereby a bit line precharge voltage VBLP is not applied to the sense-amplifier lines (SA, /SA).
After that, as shown in FIG. 9 ( c ), a word line WL is selected as shown in FIG. 10 ( g ), and a voltage division is performed to the first bit line BITH and the sense-amplifier line SA as shown in FIGS. 10 ( k ) and 10 ( l ).
Next, as shown in FIG. 9 ( d ), since there is a voltage difference between the two sense-amplifier lines (SA, /SA) as shown in FIGS. 10 ( k )- 10 ( l ) because of a voltage division, the bit line cut-off signals (BISH 1 , BISH 2 ) are disabled as shown in FIGS. 10 ( a )- 10 ( b ), and the second NMOS transistor MN 2 comprising the first line connector 21 and the third NMOS transistor MN 3 comprising the second line connector 22 are turned off, thereby separating the first bit lines (BITH, /BITH) from the sense-amplifier lines (SA, /SA).
Then, as shown in FIG. 9 ( e ), sense-amplifier control signals (RTO, /S) are enabled as shown in FIGS. 10 ( i )- 10 ( j ), so that an amplified signal is applied to the sense-amplifier lines (SA, /SA).
At this time, a loading is lowered because the first bit lines (BITH, /BITH) are isolated from the sense-amplifier lines (SA, /SA), so that a sensing operation rapidly occurs and a transient current is decreased. In addition, a power line bouncing is reduced through a peak reduction of the transient current.
In the conventional bit line sense-amplifier structure, the first bit line /BITH is moved to a high or a low level state according to a sense-amplifier operation, and is then moved to a half Vcc level. The present invention prevents does not require this conventional operation by isolating the first bit line /BISH from the sense-amplifier line, thereby preventing an unnecessary current-consumption.
After that, the second NMOS transistor MN 2 comprising the first line connector 21 and the third NMOS transistor MN 3 comprising the second line connector 22 are turned on by enabling the first bit line cut-off signals (BISH 1 , BISH 2 ) shown in FIGS. 10 ( a )- 10 ( b ), so that the first bit lines (BITH, /BITH) are connected to the sense-amplifier lines (SA, /SA). At this time, a write-back operation to the unit cell 1 is performed as shown in FIG. 10 ( k ), and a potential level of the sense-amplifier line SA may be slightly lowered as shown in FIG. 10 ( k ).
Accordingly, as shown in FIG. 9 ( f ), a full write-back operation is performed.
As to a difference between the third method and the second method, the second method separately controls the first bit lines (BISH 1 , BISH 2 ), thus two lines on which the bit line cutoff-signals. (BISH 1 , BISH 2 ) are applied are additionally needed. However, the third method controls the bit line cut-off signals (BISH 1 , BISH 2 ) with one line, and simultaneously performs a full write-back operation.
After that, the fifth, sixth, and seventh NMOS transistors (MN 5 , MN 6 , MN 7 ) comprising the bit line equalization unit 4 is turned on by enabling the bit line equalization signal BLP as shown in FIG. 10 ( e ), thereby interconnecting the sense-amplifier lines (SA, /SA) as shown in FIG. 9 ( g ). At this time, these lines (SA, /SA) have a half Vcc voltage according to a voltage division. Then, as shown in FIG. 9 ( h ), a precharge operation is performed.
That is, as shown in FIGS. l 0 ( c )- 10 ( d ), the 10th NMOS transistor MN 10 comprising the third line connector 31 and the 11th NMOS transistor MN 11 comprising the fourth line connector 32 are turned on by enabling the bit line cut-off signals (BISL 1 , BISL 2 ), thereby interconnecting the second bit lines (BITL, /BITL) and the sense-amplifier lines (SA, /SA). As shown in FIG. 10 ( f ), the fourth NMOS transistor MN 4 comprising the bit line precharge unit 10 is turned on by enabling the bit line precharge signal CON_VBLP, thereby a bit line precharge voltage VBLP is applied to the first and second bit lines (BITH, /BITH, BITL, /BITL) and the sense-amplifier lines (SA, /SA).
At this time, since the sense-amplifier lines (SA, /SA) and the first bit lines (BITH, /BITH) are at a half Vcc level, if the bit line precharge voltage VBLP is applied to the lines (BITH, /BITH, BITL, /BITL, SA, /SA), there is no power-consumption.
FIG. 11 shows a magnitude of a current measured at a ground terminal Vss in the bit line sense-amplifier of the first method; FIG. 12 shows a magnitude of a current measured at a ground terminal Vss in the bit line sense-amplifier of the second method; FIG. 13 shows a magnitude of a current measured at a ground terminal Vss in the bit line sense-amplifier of the third method; and FIG. 14 shows a magnitude of a current measured at a ground terminal Vss in the bit line sense-amplifier of the conventional art.
Referring to FIGS. 11-14, as to each average current magnitude of the first to third methods and the conventional art, an average current magnitude of the conventional art is 0.43648 mA, an average current magnitude of the first method is 0.43528 mA, an average current magnitude of the second method is 0.30721 mA, and an average current magnitude of the third method is 0.39230 mA. In conclusion, the second method is the most effective method in the light of a power-consumption.
Since each of four bit line cut-off signals is separately constructed in the bit line sense-amplifier circuit according to the present invention, each four bit line cut-off signal is separately described in the first method and the third method. But, in fact, the present invention achieves a simultaneous control by using only two lines on which a bit line cut-off signals is applied.
In the sense-amplifier control signals (RTO, /S), the present invention performs a precharge operation after completing an equalization to a precharge voltage, thereby reducing a power-consumption like as a precharge of a sense-amplifier line.
As described above, the present invention reduces a power-consumption by performing a precharge operation after completing an equalization operation, increases a sensing speed by separating the bit lines from the sense-amplifier lines in a sensing operation, and reduces a bouncing of a power-line by restraining a transient current.
It is understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the scope and spirit of this invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled in the art which this invention pertains.
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A bit line sense-amplifier for a semiconductor memory device and a method for driving the same do not apply a bit line precharge voltage by a switch in an equalization operation, perform an equalization operation by interconnecting a plurality of sense-amplifier lines, then perform a precharge operation by applying a bit line precharge voltage through NMOS transistor of the switch, increase a sensing speed by reducing a loading of a sense-amplifier, reduce a transient current, and minimize a power-consumption by performing a precharge operation after a bit line equalization.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of PCT/EP2010/064081 filed Sep. 23, 2010, that claims the benefit of the priority date of Italian Patent Application No. MI2009A001621 filed Sep. 23, 2009, the contents of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates to an electrode for electrolytic processes and a method of manufacturing thereof.
BACKGROUND OF THE INVENTION
[0003] The use of metallic electrodes provided with catalytic coatings in electrolytic applications is known in the art. Electrodes comprising a metal base (for instance made of titanium, zirconium or other valve metals, nickel, stainless steel, copper or alloys thereof) equipped with a coating based on noble metals or alloys thereof are, for instance, used as hydrogen-evolving cathodes in water or chlor-alkali electrolysis processes. In the case of cathodes for hydrogen electrolytic evolution, particularly relevant are coatings containing ruthenium, as metal or more frequently as ruthenium oxide, optionally in admixture with valve metal oxides. Electrodes of such kind may be produced by thermal processes, through the decomposition of precursor solutions of the metals to be deposited by suitable thermal treatments, or less frequently by galvanic electrodeposition from suitable electrolytic baths.
[0004] These preparation methods are capable of producing ruthenium catalysts characterised by a great variability of crystal lattice parameters, presenting a fair catalytic activity towards hydrogen evolution reaction, non perfectly correlated with the crystallite average size. The best catalysts produced by thermal decomposition of salt precursor solutions can, for instance, present a crystal average size of about 10-40 nm with a standard deviation of 2-3 nm, the relevant catalytic activity being moderately increased for samples at the lower end of the range.
[0005] In an industrial electrolytic process, the catalytic activity of the electrodes is directly reflected on the operating voltage of the electrolysers, and therefore on energy consumption. For this reason, it would be desirable to obtain catalysts with an increased activity towards gas evolution reactions, for instance towards the reaction of cathodic hydrogen evolution.
SUMMARY OF THE INVENTION
[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key factors or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. As provided herein, the invention comprises, under one aspect an electrode for hydrogen evolution comprising a metal substrate provided with a superficial catalytic coating containing crystallites of ruthenium in the form of metal or of oxide, having a size of 1 to 10 nm with a standard deviation not higher than 0.5 nm as obtained by repeating the measurement in a different zones of said superficial catalytic coating.
[0007] In another aspect, the invention comprises a method for manufacturing an electrode comprising the deposition of a catalytic coating by means of a chemical or physical vapour deposition technique from a ruthenium target, the catalytic coating comprising crystallites of ruthenium in the form of metal or of oxide, having a size of 1 to 10 nm with a standard deviation not higher than 0.5 nm as obtained by repeating the measurement in a different zones of the superficial catalytic coating.
[0008] In a further aspect, the invention comprises the use of an electrode for cathodic evolution of hydrogen in an electrolytic process, the electrode comprising a metal substrate provided with a superficial catalytic coating containing crystallites of ruthenium in the form of metal or of oxide, having a size of 1 to 10 nm with a standard deviation not higher than 0.5 nm as obtained by repeating the measurement in a different zones of said superficial catalytic coating.
[0009] To the accomplishment of the foregoing and related ends, the following description sets forth certain illustrative aspects and implementations. These are indicative of but a few of the various ways in which one or more aspects may be employed. Other aspects, advantages, and novel features of the disclosure will become apparent from the following detailed description.
DESCRIPTION
[0010] The inventors surprisingly observed that hydrogen evolution reaction proceeds with improved kinetics if carried out on metal substrates provided with a superficial catalytic coating containing crystallites of ruthenium, in form of metal or of oxide, having very reduced and very narrow lattice parameters, for instance of size comprised in one embodiment between 1 and 10 nm, and in one embodiment between 1 to 5 nm, with a standard deviation not higher than 0.5 nm. Catalysts with these characteristics and with the usual noble metal loadings, for instance 5 to 12 g/m 2 of ruthenium expressed as metal, can be capable of decreasing the reduction potential of hydrogen of 20-30 mV with respect to the best catalysts of the prior art. In one embodiment, an electrode provided with a catalytic coating having a crystallite size of 1 to 10 nm, optionally 1 to 5 nm, with a standard deviation not higher than 0.5 nm, can be obtained by subjecting a metal substrate, for example a nickel substrate, to a chemical or physical vapour deposition treatment of ruthenium, wherein such deposition is suitably controlled so as to produce the desired lattice parameters.
[0011] The size of crystallites can be adjusted for instance by acting on the temperature of the metal substrate, on the degree of vacuum of the deposition process, on the energy level of an ion plasma used to bomb the substrate during the deposition phase or on several other parameters, specific of the various applicable techniques. In one embodiment, a physical vapour deposition of ruthenium is obtained by means of an IBAD technique, providing the generation of plasma at a pressure of 10 −6 -10 −3 Pa, the extraction of ruthenium ions from targets of ruthenium metal arranged in the deposition chamber under the action of plasma assisted by an ion beam and the consequent bombardment of the substrate to be treated with a beam containing ruthenium ions at an energy of 1000 to 2000 eV. In one embodiment, the Ion Beam Assisted Deposition (IBAD) deposition is of dual type, that is preceded by a step of substrate cleaning by bombardment with in situ-generated argon ions at a lower energy level (200-500 eV).
[0012] In one embodiment, a physical vapour deposition of ruthenium is obtained by means of a MPS (Magnetron Plasma Sputtering) technique, providing the generation of high density plasma through the combined use of a magnetic field and a radiofrequency electric field, or by a DC Plasma Sputtering technique, providing the generation of high density plasma through the combined use of a magnetic field and modulated direct current.
[0013] In one embodiment, a physical vapour deposition of ruthenium in the form of an oxide, for instance, of non-stoichiometric dioxide characterised by particularly high catalytic activity and stability at the usual industrial electrolysis conditions, is obtained by means of a physical vapour deposition according to one of the above described methodologies carried out in the presence of a reactant gas, for instance oxygen, so as to produce the simultaneous oxidation of the deposited ruthenium. Alternatively, it is possible to deposit ruthenium directly from ruthenium oxide targets.
[0014] The inventors observed that the effect of size and regularity of the crystallites on the reaction kinetics is significant, especially for the outermost portion of the catalyst, directly in contact with the process electrolyte. Hence, in one embodiment, a hydrogen-evolving electrode comprises a substrate coated with an intermediate catalytic coating of ruthenium dioxide which can be prepared galvanically or by thermal decomposition of salt precursors, whereon a superficial catalytic coating is applied comprising crystallites of ruthenium, in metal or oxide form, having a size of 1 to 10 nm, more preferably 1 to 5 nm, with a standard deviation not higher than 0.5 nm, wherein such coating can be prepared by chemical or physical vapour deposition. In one embodiment, the intermediate catalytic coating has a specific loading of 5-12 g/m 2 of ruthenium expressed as metal, and the superficial catalytic coating has a specific loading of 1-5 g/m 2 of ruthenium expressed as metal. This can have the advantage of allowing the application of the main amount of catalyst by a quicker and cheaper method, using the PVD or CVD techniques only to deposit the outermost layer which is more affected by the benefits of a controlled size distribution of the crystallites.
[0015] Some of the most significant results obtained by the inventors are presented in the following examples, which are not intended as a limitation of the extent of the invention.
EXAMPLE 1
[0016] A flattened mesh of nickel 200 of 1000 mm×500 mm×0.89 mm size was subjected to a blasting treatment with corundum until obtaining a controlled roughness, with an R z value of 70 μm. The blasted mesh was then etched in 20% boiling HCl to eliminate possible corundum residues.
[0017] The thus-treated mesh was loaded in a Magnetron Plasma Sputtering device of the type provided with a conditioning chamber operated at a first vacuum level (typically 10 −3 Pa) and with a deposition chamber operated at high vacuum, equipped with a ruthenium metal target. Upon reaching a vacuum level of 5·10 −5 Pa in the deposition chamber, the generation of a pure Ar plasma was activated between the mesh and the chamber walls. Upon completion of this phase, aimed at obtaining a perfect cleaning of the surface, the generation of plasma was activated between the ruthenium target (99% w/w, 200 W nominal power, zero reflected power) simultaneously feeding a 20% oxygen in argon gas mixture thereby establishing a dynamic vacuum of 10 −1 Pa. This triggered the onset of the reactive deposition of a RuO 2 layer. During the deposition, the sample holder housing the mesh was rotated to optimise the homogeneity. The deposition was repeated on the opposite side of the mesh, until obtaining a total loading of 9 g/m 2 of Ru expressed as metal. The ex situ measurement of crystallite size, mediated according to Scherrer across a 4 cm 2 surface, showed a value of 4.0 nm. By repeating the measurement in different zones of the samples, the standard deviation obtained was 0.5 nm. A hydrogen evolution potential of −930 mV/NHE was detected in 32% caustic soda at a temperature of 90° C. and at a current density of 3 kA/m 2 .
EXAMPLE 2
[0018] A flattened mesh of nickel 200 of 1000 mm×500 mm×0.89 mm size was subjected to a blasting treatment with corundum until obtaining a controlled roughness, with an R z value of 70 μm. The blasted mesh was then etched in 20% boiling HCl to eliminate possible corundum residues.
[0019] The thus-treated mesh was activated with 8 g/m 2 of ruthenium, expressed as metal, by thermal decomposition of a RuCl 3 .3H2O hydroalcoholic solution acidified with HCl. The solution was applied in four coats by spraying and subsequent thermal treatment in a vented oven at 480° C. for 10 minutes. After the last coat, a final thermal treatment of 1 hour at the same temperature was carried out.
[0020] The preactivated mesh was then loaded in a Magnetron Plasma Sputtering device analogous to the one of example 1. Upon reaching a vacuum level of 5·10 −5 Pa in the deposition chamber, the generation of a pure Ar plasma was activated between the mesh and the chamber walls. Upon completion of this surface cleaning phase, the generation of plasma was activated between the ruthenium target (99% w/w, 200 W nominal power, zero reflected power) simultaneously feeding a 20% oxygen in argon gas mixture thereby establishing a dynamic vacuum of 10 −1 Pa. This triggered the onset of the reactive deposition of a RuO 2 layer. During the deposition, the sample holder housing the mesh was rotated to optimise the homogeneity. The deposition was repeated on the opposite side of the mesh, until obtaining a total loading of 4 g/m 2 of Ru expressed as metal. The ex situ measurement of crystallite size by low angle X-Ray diffraction technique showed a value of 4.0+/−0.5 nm. A hydrogen evolution potential of −930 mV/NHE was detected in 32% caustic soda at a temperature of 90° C. and at a current density of 3 kA/m 2 .
Counterexample 1
[0021] A flattened mesh of nickel 200 of 1000 mm×500 mm×0.89 mm size was subjected to a blasting treatment with corundum until obtaining a controlled roughness, with an R z value of 70 μm. The blasted mesh was then etched in 20% boiling HCl to eliminate possible corundum residues.
[0022] The thus-treated mesh was activated with 12 g/m 2 of ruthenium, expressed as metal, by thermal decomposition of a RuCl 3 .3H 2 O hydroalcoholic solution acidified with HCl. The solution was applied in five coats by spraying and subsequent thermal treatment in a vented oven at 550° C. for 10 minutes. After the last coat, a final thermal treatment of 1 hour at the same temperature was carried out.
[0023] The ex situ measurement of crystallite size by low angle X-Ray diffraction technique showed a value of 20+/−2 nm. A hydrogen evolution potential of −950 mV/NHE was detected in 32% caustic soda at a temperature of 90° C. and at a current density of 3 kA/m 2 .
Counterexample 2
[0024] A flattened mesh of nickel 200 of 1000 mm×500 mm×0.89 mm size was subjected to a blasting treatment with corundum until obtaining a controlled roughness, with an R z value of 70 μm. The blasted mesh was then etched in 20% boiling HCl to eliminate possible corundum residues.
[0025] The thus-treated mesh was activated with 13 g/m 2 of ruthenium, expressed as metal, by thermal decomposition of a RuCl 3 .3H 2 O hydroalcoholic solution acidified with HCl. The solution was applied in five coats by spraying and subsequent thermal treatment in a vented oven at 460° C. for 10 minutes. After the last coat, a final thermal treatment of 1 hour at the same temperature was carried out.
[0026] The ex situ measurement of crystallite size by low angle X-Ray diffraction technique showed a value of 16+/−2 nm. A hydrogen evolution potential of −945 mV/NHE was detected in 32% caustic soda at a temperature of 90° C. and at a current density of 3 kA/m 2 .
Counterexample 3
[0027] A flattened mesh of nickel 200 of 1000 mm×500 mm×0.89 mm size was subjected to a blasting treatment with corundum until obtaining a controlled roughness, with an R z value of 70 μm. The blasted mesh was then etched in 20% boiling HCl to eliminate possible corundum residues.
[0028] The thus-treated mesh was then loaded in a Magnetron Plasma Sputtering device analogous to the one of example 1. While reaching a vacuum condition of 5·10 −5 Pa in the deposition chamber, the temperature of the sample was brought to 450° C. by means of an electric resistance. The generation of a pure Ar plasma was then activated between the mesh and the chamber walls. Upon completion of this surface cleaning phase, the generation of plasma was activated between the ruthenium target (99% w/w, 200 W nominal power, zero reflected power) simultaneously feeding a 20% oxygen in argon gas mixture thereby establishing a dynamic vacuum of 10 −1 Pa. This triggered the onset of the reactive deposition of a RuO 2 layer. During the deposition, the sample holder housing the mesh was rotated to optimise the homogeneity. The deposition was repeated on the opposite side of the mesh, until obtaining a total loading of 9 g/m 2 of Ru expressed as metal. The ex situ measurement of crystallite size, mediated according to Scherrer across a 4 cm 2 surface, showed a value of 35 nm. By repeating the measurement in different zones of the samples, the standard deviation obtained was 0.5 nm. A hydrogen evolution potential of −962 mV/NHE was detected in 32% caustic soda at a temperature of 90° C. and at a current density of 3 kA/m 2 .
[0029] The previous description is not intended to limit the invention, which may be used according to different embodiments without departing from the scopes thereof, and whose extent is univocally defined by the appended claims.
[0030] Throughout the description and claims of the present application, the term “comprise” and variations thereof such as “comprising” and “comprises” are not intended to exclude the presence of other elements or additives.
[0031] The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention before the priority date of each claim of this application.
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The invention relates to a cathode for electrolytic processes provided with a catalytic coating based on ruthenium crystallites with highly controlled size falling in a range of 1-10 nm. The coating can be produced by physical vapour deposition of a ruthenium or ruthenium oxide layer.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a hinge damper of an opening/closing device that enables smooth and safe opening/closing of an opening/closing member of a document pressing plate of a copier or an opening/closing member of a toilet seat.
[0003] 2. Related Art
[0004] Conventionally, in an opening/closing device of a document pressing plate that includes an attachment member that is attached to an apparatus body such as a copier, a support member that can freely rotate and support the document pressing plate while being pivotally attached to the attachment member, and a compressed coil spring that is inserted between the attachment member and the support member while biasing the document pressing plate to the opening direction thereof, there is a technique that prevents the document pressing plate from suddenly falling because the weight of the document pressing plate overcomes the bias of the pressed coil spring and resultingly prevents a hand of the user from being caught between the plate and the apparatus body or the position of the document being moved (for example, refer to Patent Document 1).
[0005] However, the above-mentioned conventional technique to prevent the document pressing plate from sudden falling uses an oil damper and therefore has the following problems:
1. As the damper absorbs energy in the loading direction, rigidity is required for the case that receives a piston; 2. Since it is made of metal such as die-cast, the damper is heavy. In addition, since it becomes long in its axial direction, the damper requires space for installation; 3. To put it in a coil spring in a hinge, the spring itself is large-sized; 4. Since the oil viscosity resistance is converted into heat energy, it comes to possess high temperature when used continuously. Moreover, since the oil viscosity resistance depends on the outside temperature, it is unstable. Therefore, there may be cases where the damper does not function well when the opening/closing device is opened and closed in succession; 5. If the document pressing device is closed forcibly, overload is applied to the damper to raise the oil pressure inside thereof, which may lead to a damage; 6. Since the piston rod of the damper is prone to eccentric loading, it must be operated with high accuracy and may easily cause oil leakage and/or breakage of the device; 7. Oil or water around the damper may adhere on the piston rod, causing damage to a packing or malfunctioning; 8. When disposed, it requires an environmental measure due to oil or the like, and; 9. Since the oil depends on the outside temperature, when used in a location that is not kept in room temperature, performance of the damper differs significantly.
Patent Reference 1: Japanese Utility Model Publication No. 2589714
[0015] The purpose of the present invention is to provide a hinge damper of an opening/closing device that can solve the above mentioned problems and is light weight, small, stable even when used for a long period of time, and easy to perform maintenance.
SUMMARY OF THE INVENTION
[0016] A hinge damper of the present invention includes an attachment member to be attached to an apparatus body such as a copier, a support member that can freely rotate and support a open/close member such as a document pressing plate while being pivotally attached to the attachment member, a compressed coil spring that is inserted between the attachment member and the support member while biasing the open/close member toward its opening direction, and an elastic body such as urethane elastomer foam, wherein a rotation axis that is rotated according to the rotation of a rotation member and is pivotally attached to a case to be able to rotate, a gearing that is attached to the rotation axis while having internal teeth, means for transferring the rotation of the open/close member to the gearing, a gear planet that is engaged with the internal teeth of the gearing, rotation control means that regulates the rotation of the gear planet so that its center performs circular locus movement around the rotation center of the gearing, and means that absorb the rotation energy of the gearing are included. In addition, the means that transfers the rotation of the open/close member to the gearing is a sector gear. Moreover, the means that regulates the rotation of the gear planet has an actuation pin that is implanted in the gear planet and a bush that has a hole to which the actuation pin is inserted so that the action of the pin is regulated. Furthermore, the means to absorb the rotation energy of the gearing has a friction tooth formed on the gearing and a plate planet having wave-shape periphery surface on which the friction tooth slides. Still furthermore, the hinge damper is incorporated into the attachment member of the open/close member.
[0017] The hinge damper of the present invention has following advantages; it has a large capacity to absorb energy thanks to the structure of a small damper function, is light weight and small, stable when used for a long period of time, and is easy to perform maintenance. Moreover, there is another advantage that as it does not use oil like conventional oil dampers, problems mentioned above can be avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A is a side-view of an opening/closing device of a document pressing plate having a hinge damper of the present invention and 1 B is a view showing its function.
[0019] FIG. 2 is an external view of the hinge damper.
[0020] FIG. 3 is a perspective view of a hinge damper that is disassembled in a support axis direction.
[0021] FIG. 4 is a cross sectional view of the hinge damper.
[0022] FIG. 5 is a cross sectional view taken along a line A-A of FIG. 4 .
[0023] FIG. 6 is a cross sectional view taken along a line B-B of FIG. 4 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Hereinafter, an embodiment of a hinge damper of an opening/closing device of the present invention will be described referring to figures.
[0025] In FIG. 1 , P is a document pressing plate which is attached to M, a main body of a copier or the like, via an H, which is an opening/closing device. P can open/close freely. The opening/closing device H mainly includes an attachment member 1 which is attached to the main body M, a support arm 3 which is pivotally attached to the attachment member 1 via a hinge axis 2 so as to allow the support arm 3 to freely move in a rotational manner, and a lift arm 5 which is pivotally attached to a tip of the support arm 3 via a support axis 4 so as to allow the lift arm 5 to freely move in a rotational manner.
[0026] In the support arm 3 , a first slider 6 and a second slider 7 are installed while enabling them to freely slide in a longitudinal direction. Between the first and second sliders 6 and 7 , a compressed coil spring 8 is inserted. Instead of the compressed coil spring 8 , an urethane elastomer foam may be used. A cam follower 6 a of the first slider 6 is attached to a cam part 9 placed on the attachment member 1 , while a cam follower 7 a of the second slider 7 is attached to a front side plate 5 a of the lift arm 5 . Note that the opening/closing device H of the present invention is not limited to the structure described above and any conventional structure, for example, one in which the support axis 4 and the lift arm 5 are not included and the document pressing plate P is attached and fixed to the support arm 3 , may be used.
[0027] In the attachment member 1 which is in the vicinity of the hinge axis 2 , a case 10 of the hinge damper is provided.
[0028] FIG. 2 shows external appearance of the case 10 of the hinge damper and the case 10 includes a case body 10 a and a lid 10 b . 11 is an attachment frame for attaching the case 10 to the opening/closing device H. In the case 10 , as shown in FIG. 3 which is an exploded diagram, a hinge damper is installed.
[0029] In FIG. 3, 12 is a sector gear, 13 is a small gear, 14 is a support axis, 15 is a first internal tooth gear, 16 is a first gear planet, 17 a is a first eccentric shaft, 17 b is a second eccentric shaft, 18 is a second internal tooth gear, 19 is a second gear planet, 20 is a third internal tooth gear, 21 is a third gear planet, 22 a is a third eccentric shaft, 22 b is a fourth eccentric shaft, 23 is a fourth internal tooth gear, and 24 is a fourth gear planet.
[0030] As apparent from FIG. 5 , the sector gear 12 is attached and fixed to the hinge axis 2 of the opening/closing device H and rotates along with the rotation of the hinge axis 2 . On the sector gear 12 , along the rotation angle thereof that is almost equal to the rotation angle of the opening/closing device H, teeth 12 a are formed.
[0031] The small gear 13 is attached to freely rotate around the support axis 14 and is engaged with the sector gear 12 . A flange portion 13 a is provided to the small gear 13 in an integrated manner. The flange portion 13 a has a plain part 13 a ′. On the tip of the support axis 14 , a square-headed bolt 14 a is provided and is fitted into a square hole 11 a of the attachment frame 11 to prevent it from rotating.
[0032] As apparent from FIG. 5 , the flange portion 13 a of the small gear 13 is fitted into a hole 15 a formed on the first internal tooth gear 15 and a plain part 15 a ′ thereof is attached to the plain part 13 a ′ of the flange portion 13 so that they are rotated in an integrated manner.
[0033] As shown in FIG. 6 , teeth 16 a of the first gear planet 16 is engaged with teeth 15 a of the first internal tooth gear 15 and can roll. The first gear planet 16 is attached to the first eccentric shaft 17 a and can freely rotate. The first eccentric shaft 17 a is attached to the support axis 14 and cannot rotate. Therefore, the first gear planet 16 rotates in a condition where it is decentered to the central axis of the support axis 14 .
[0034] As apparent from FIG. 4 , the second internal tooth gear 18 is connected to the first gear planet 16 so that they rotate in an integrated manner. The second internal tooth gear 18 is engaged with the second gear planet 19 so that they rotate in an integrated manner. The second gear planet 19 is attached so that it rotates in a condition where it is decentered to the second eccentric shaft 17 b . The first eccentric shaft 17 a and the second eccentric shaft 17 b are located to be symmetric to the central axis of the support axis 14 .
[0035] The third internal tooth gear 20 is connected to the second gear planet 19 so that they can rotate in an integrated manner. The third gear planet 21 is engaged with the third internal tooth gear 20 so that they can rotate in an integrated manner. The third gear planet 21 is attached so that it rotates in a condition where it is decentered to the third eccentric shaft 22 a.
[0036] The fourth internal tooth gear 23 is connected to the third gear planet 26 so that they can rotate in an integrated manner. The fourth internal tooth gear 23 is engaged with the fourth gear planet 24 so that they can rotate in an integrated manner. The fourth gear planet 24 is attached so that it rotates in a condition where it is decentered to the fourth eccentric shaft 22 b . The third eccentric shaft 22 a and the fourth eccentric shaft 22 b are located to be symmetric to the central axis of the support axis 14 .
[0037] Because the hinge damper of the present embodiment is structured as above, when the document pressing plate P is closed as in FIG. 1 (B) to the arrow direction, the sector gear 12 integrated with the hinge axis 2 is rotated counterclockwise, as indicated by an arrow in FIG. 2 , and turns the small gear 13 clockwise.
[0038] When the small gear 13 rotates, together with this movement, the first internal tooth gear 15 rotates and the first gear planet 16 that is engaged with the internal tooth gear 15 rotates in the same direction. The number of teeth N of the first internal tooth gear 15 is more than the number of teeth of the first gear planet 16 n (N>n). Therefore, when the first internal tooth gear 15 is rotated 360°, speed of the first gear planet 16 is increased for the N/n times of rotation.
[0039] The rotation of the first gear planet 16 also increases the speed of the second gear planet 19 via the second internal tooth gear 18 . Thus, the speed of the third gear planet 21 and the fourth gear planer 24 are increased sequentially.
[0040] Due to the engagement friction (resistance) of each internal gear and gear planet, the rotation energy is absorbed.
[0041] Means to transfer the rotation of the opening/closing device H is not limited to the above mentioned sector gear or other kind of gear and a power transmission mechanism such as a belt or a link may be used.
[0042] The opening/closing device of the hinge damper of the present invention is not limited to the above mentioned document pressing plate of a copier, but is applicable to hinge that opens/closes an open/close member of a scanner, a fax, or a lid of a toilet seat.
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A hinge damper is comprised of a rotation axis that is rotated according to the rotation of a rotation member and is pivotally attached to a case to be able to rotate freely, a gearing that is attached to the rotation axis to be able to freely rotate while having an internal tooth, means for transferring the rotation of the open/close member to the gearing, a gear planet that is engaged with the internal tooth of the gearing, rotation control means that regulates the rotation of the gear planet so that its center performs circular locus movement around the rotation center of the gearing, and means that absorbs the rotation energy of the gearing.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a sheet-fed printing machine or press, composed of units in an in-line construction.
Such printing machines are made up of individual offset printing units, flexographic printing units (varnishing or coating units) and finishing units (perforating, stamping, embossing units or the like); the aforementioned sheet processing units are disposed in an order that suits the customer-specific requirements.
In one case, for example, it may be necessary for the flexographic printing unit to precede the offset printing units, while in another case the flexographic printing unit is downline of the offset printing units (note the published European Patent Document EP 0 620 115 B1, FIGS. 1 and 2). The number of offset printing units and the number of flexographic printing units can also differ from one printing machine to another.
In the interest of rationalizing the manufacture of printing machines, printing machine manufacturers have created a building block or modular system for every model series of printing machine in question; such a system includes the various sheet processing units and other assemblies (such as an inverter, a sheet delivery, and so forth) of that particular model series. However, within one building block system, there are structural differences between the so-called feeder printing unit on the one hand and the printing units located in the second, third, fourth position and so forth.
The special feature of a feeder printing unit is, in fact, that it includes a sheet feeder system, which can, for example, include a pre-gripper and a feed drum (note the published German Patent Document DE 30 08 226 C2), and that it is embodied in a special manner in the interest of integrating the sheet feeder system. The structural consideration as to whether a sheet processing unit is disposed first, in terms of the sheet transport direction, or in the first position that follows the sheet separating unit, results in increased production costs.
It has also not been possible to solve this problem with the sheet-fed printing presses described in the published German Patent Documents DE 42 30 568 A1, DE 44 35 307 A1, and DE 296 23 064 U1 (the latter for a German utility model).
In the published German Patent Document DE 43 43 616 A1, a modular printing press system is described which includes printing presses which process sheets of paper, and printing presses which process sheets of cardboard; these printing presses are assembled from prefabricated structural groups in accordance with the needs of the customer. The manufacturer selectively equips the printing presses with a standard feeder and with a standard feed assembly, the latter including a feed drum and a pre-gripper, so as to make it possible to process the sheets of paper. By an exchange of assemblies, wherein, instead of the standard feeder, a tall stack or pile feeder, and instead of the standard feed assembly, a tall-version feed assembly are used, the printing press can be selectively equipped, without further modifications or adaptations in the production process, to process the sheets of cardboard as well. The last German patent document identified hereinabove accordingly teaches that for every type of printing press within a building block system, a different, special feed assembly must be used. It is true that in this way a customer-specific and yet rapid outfitting of the printing press or printing machine is possible, but the production costs cannot be lowered sufficiently in this way.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to provide a sheet-fed printing machine by the structural features of which the manufacture of the printing machine can be rationalized further.
With the foregoing and other objects in view, there is provided, in accordance with the invention, a sheet-fed printing machine made up of units in an in-line construction, comprising a sheet-feeding unit disposed between a sheet separating unit and a sheet processing unit following the sheet separating unit, the sheet feeding unit being formed so that it is selectively pre-arrangeable upline from various types of sheet processing units for creating various types of sheet-fed printing machines of a building block system.
In accordance with another feature of the invention, the sheet processing unit is a printing unit.
In accordance with a further feature of the invention, the sheet-fed printing machine includes at least another sheet processing unit following the sheet separating unit, the sheet-feeding unit being disposed between the sheet separating unit and a first one of the sheet processing units.
In accordance with an added feature of the invention, the sheet feeding unit includes at least one lay mark.
In accordance with an additional feature of the invention, the sheet feeding unit includes a pre-gripper.
In accordance with yet another feature of the invention, the sheet feeding unit includes a feed drum.
In accordance with yet a further feature of the invention, the sheet feeding unit includes a sheet transport drum.
In accordance with yet an added feature of the invention, the sheet transport drum is of multiple size.
In accordance with yet an additional feature of the invention, the printing unit is a flexographic printing unit.
In accordance with still another feature of the invention, the printing unit includes a zoneless metering device.
In accordance with a concomitant feature of the invention, the metering device includes a screen roller and a chambered doctor blade.
In a building block system including such printing machines as are produced in accordance with the invention, an advantage is attained in that the sheet processing unit, when disposed in a first position downline can be embodied structurally exactly the same as when disposed at the second, third, fourth or later positions. By reducing the number of modified forms of the sheet processing units within the building block system, greater rationalization of production is achieved, and production costs are consequently reduced.
Increased modularity of the building block system is also attained as a result of the fact that advantageously one and the same sheet feeding unit can be disposed preceding various kinds of sheet processing units, as needed. For example, the sheet feeding unit in one printing machine can immediately precede an offset printing unit, while in another printing machine it can immediately precede a flexographic printing unit. At least one offset printing unit can be disposed following the offset or flexographic printing unit that is immediately preceded by the sheet feeding unit.
The sheet separating or singling unit serves to single out or separate the sheets of printing material from a pile of sheets, and thereafter transports the sheets, separated from the sheet pile, to the sheet feeding unit either as single sheets or in a stream arrangement.
The function of the sheet feeding unit is to take over the sheets, which arrive from the sheet separating unit, and transfer these sheets in-register to the sheet processing unit. The sheet feeding unit is thus required to have only one sheet transporting device and/or one sheet aligning device. The sheet feeding unit does not have to include a device for processing the sheets, such as a printing device.
Hereinafter described and in various respects advantageous improvements in the sheet-fed printing machine according to the invention are possible.
The sheet aligning device of the sheet feeding unit can be formed of a front lay mark and/or a side lay mark. The sheet transport device of the sheet feeding unit can be formed of an oscillating pre-gripper and/or a revolving feed drum.
In addition to the pre-gripper and/or the feed drum, a sheet transport drum can be rotatably mounted in the sheet feeding unit; the transport drum is disposed between the sheet aligning device and a cylinder of the sheet processing unit.
The circumference of the sheet transport drum can be twice as large, or more than twice as large, as the sheet format length.
In one possible embodiment of the sheet processing unit as a finishing unit, this unit can include a cutting tool for severing the sheet, such as a perforating tool, for example; or a deforming tool for deforming the sheet, such as an embossing tool, for example; or a cleaning tool for cleaning the sheet, such as a dust removing brush, for example.
The sheet processing unit can, however, also be embodied as an offset press unit, a letterpress unit, or a flexographic printing unit. The latter can, for example, precede a plurality of offset printing units of the sheet-fed printing press and can serve the purpose of coating the sheet over the full surface thereof or selected areas thereof with an opaque or zinc white, a metallic-effect ink, a varnish, or the like.
With such use of the printing unit as a coating unit, this printing unit can be equipped with a zoneless metering device for metering the ink or varnish uniformly over the printing width. For example, the metering device can be formed of an immersion or dip roller disposed in a tub of ink or varnish, and a metering roller in contact with the dip roller; together, these rollers define a metering gap that is adjustable with respect to what can pass therethrough.
The metering device is preferably formed of a screen or anilox roller, however, against which a chambered doctor blade lies.
The sheet-fed printing machine can be embodied as an offset rotary printing machine, a flexographic rotary printing machine, or a so-called hybrid printing machine. A hybrid printing machine is distinguished in that it has at least two printing units which print in accordance with mutually different printing principles (such as an offset printing unit and a flexographic printing unit, for example).
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a sheet-fed printing machine, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a sheet-fed printing machine, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings wherein:
BRIEF DESCRIPTION OF THE DRAWING
The single unidentified FIGURE is a diagrammatic side elevational view of the sheet-fed printing machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the unidentified sole FIGURE of the drawing, there is shown therein a sheet-fed printing machine or printing press 1 assembled, in the order named, from a sheet separating or singling unit 2 , a sheet feeding unit 3 , a printing unit 4 , a drying unit 5 , a further printing unit 6 , and a sheet delivery 7 , with an integrated drying system 8 .
The sheet separating unit 2 includes, as a separator device, a suction head 9 with a separating suction cup for lifting single sheets from a sheet pile 10 . The sheet separating unit 2 furthermore includes a feeder tray or feeding table 11 , which protrudes out of the sheet separating unit 2 and into the sheet feeding unit 3 . On the feeding table 11 , the sheets are transported from the sheet separating unit 2 to the sheet feeding unit 3 .
The sheet feeding unit 3 has two side walls 12 and 13 forming a frame, and further includes a lay mark or feed lay 14 , a pre-gripper 15 , a feed drum 16 , and a sheet transport drum 17 , which are supported between the side walls 12 and 13 in the sheet feeding unit 3 .
After the leading or front edge of a sheet, which has been transported to the end of the feeding table 11 , has abutted the lay mark 14 and, as a result, has been aligned parallel to the gripper edge of the pre-gripper 15 , the latter can grip 20 the sheet and transfer it to the feed drum 16 , which is embodied as a drum of standard, single size and is equipped with a single row of grippers for holding the sheet.
The sheet transport drum 17 , a sheet transport cylinder 18 of the printing unit 4 (or sheet processing unit), and an impression cylinder 19 of the printing unit 4 are each embodied double-sized, and are each provided with two diametrically opposed rows of grippers for holding the sheet.
The feed drum 16 transfers the sheet in register from the pre-gripper 15 to the sheet transport drum 17 which, in turn, transfers the sheet to the printing unit 4 (or sheet processing unit). The sheet transport cylinder 18 takes over the sheet from the sheet transport drum 17 and transfers the sheet to the impression cylinder 19 whereon the sheet is printed by an applicator cylinder 20 of the printing unit 4 .
A flexographic printing form or a rubber blanket can be mounted selectively on the applicator cylinder.
The applicator cylinder 20 is inked by a zoneless metering device of the printing unit 4 , the zoneless metering device including a screen or anilox roller 21 that rolls along the applicator cylinder 20 , and a chambered doctor blade 22 that fills the screen or dot-matrix structure with ink or varnish.
The printing unit 6 (or further sheet processing unit) is structurally identical with the printing unit 4 , except for the zoneless metering device. In the case of the printing unit 6 , the zoneless metering device does not include a screen roller and a chambered doctor blade, but instead, an ink-filled or varnish-filled tub 23 , an immersion or dip roller 24 disposed in the tub, and a metering roller 25 in contact with the dip roller 24 .
The sheet feeding unit 3 serving for aligning the sheet and transferring it with precise fit and in-register to the printing unit 4 has a frame (side walls 12 and 13 ) that is formed separately and apart from a frame, which is formed of side walls 26 and 27 , of the printing unit 4 , and a frame 28 of the sheet separating unit 2 . The frame (side walls 12 and 13 ) of the sheet feeding unit set up between the frame (side walls 26 and 27 ) of the printing unit 4 and the frame 28 is separated from the other two frames by dividing or parting lines 29 and 30 .
The side walls 12 and 13 are disposed perpendicularly to the plane of the drawing, and have a mutual spacing like that of the side walls 26 and 27 and are arranged in abutting relationship with the latter. A self-contained overall form of the sheet-fed printing machine 1 is thereby produced therefrom. The units 2 , 3 and 4 are solidly connected to one another by formlocking connections, such as screw fastenings, for example. In this regard, it is noted that a formlocking connection is one which connects two elements together due to the shape of the elements themselves, as opposed to a forcelocking connection, which locks the elements together by force external to the elements.
Reference numerals 31 and 32 , respectively, identify two drying systems of the drying unit 5 , which are directed towards a double-sized sheet transport cylinder 33 of the drying unit 5 . Reference numeral 34 identifies a third drying system of the drying unit 5 , the third drying system 34 being directed towards the impression cylinder 19 of the printing unit 4 . A further drying system 35 is also directed towards the impression cylinder 19 .
Each of the drying systems 8 , 31 , 32 , 34 and 35 can be an ultraviolet (UV), infrared (IR) or thermal air (TL) dryer.
The Reference numeral 37 refers to a different sheet-fed printing machine which includes a diagram illustrated of feet printing unit 36 . The sheet-fed printing machines 1 and 37 belong to one and the same building block system.
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A sheet-fed printing machine made up of units in an in-line construction includes a sheet-feeding unit disposed between a sheet separating unit and a sheet processing unit following the sheet separating unit. The sheet feeding unit is formed so that it is selectively pre-arrangeable upline from various types of sheet processing units for creating various types of sheet-fed printing machines of a building block system.
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TECHNICAL FIELD
[0001] The present invention relates to an electrostatic chuck for holding a workpiece plate body such as a glass substrate, a glass substrate processing method, and said glass substrate.
BACKGROUND ART
[0002] Along with recent upsizing of displays in the field of FPDs (flat panel displays), there has been a need for an apparatus that is capable of conveying and processing, for example, a G8 (8th generation) large-size glass substrate with the dimensions 2200 mm×2500 mm in the process step of processing a display.
[0003] A conventional apparatus, for example, for conveying a large-size glass substrate with use of an electrostatic holding technology, e.g. a conventional in-line deposition apparatus for deposition on a surface of a glass substrate, has had a length of several meters to several tens of meters.
[0004] As described, for example, in PTL1 and PTL2, such a deposition apparatus is configured to emit a boiled deposition material toward a surface of a large-size glass substrate from a deposition source located below the glass substrate and thereby deposit a desired circuit pattern and the like on the glass substrate surface. For this purpose, an electrostatic holding device holding the glass substrate is rotated as a whole so that the glass substrate faces downward, and the glass substrate is conveyed to a position directly above the deposition source while continuing to face downward. Then, after the deposition process, the glass substrate is released from the holding device and passed on to the next step.
CITATION LIST
Patent Literature
[0005] PTL 1: Japanese Patent Application Laid-Open No. 2011-094196 A
[0006] PTL 2: Japanese Patent Application Laid-Open No. 2010-132978 A
SUMMARY OF INVENTION
Technical Problem
[0007] However, the conventional technology described above has the following problems:
[0008] The electrostatic holding device for use in the deposition apparatus is structured such that an electrostatic holding layer formed by thermal spraying or the like is provided on a solid heavy base member made of aluminum or the like. The electrostatic holding device is conveyed while holding a glass substrate on an upper surface of the device. The conveyance is performed by moving shafts supporting the device at both edges of the base member of the device. Then, by rotating the shafts before the device is conveyed to a position directly above the deposition source, the electrostatic holding device and the glass substrate are rotated together so that the glass substrate faces downward, and the glass substrate passes directly above the deposition source while continuing to face downward.
[0009] That is, since a process apparatus such as the deposition apparatus needs to be structured to convey and rotate the very heavy electrostatic holding device while supporting it with the shafts, further upsizing of the apparatus as a whole has been inevitable.
[0010] Further, when the electrostatic holding device is conveyed or rotated while being supported by the shafts, a very large load is applied to the points at which the base member is supported by the shafts, as the electrostatic holding device is very heavy. This has caused the base member to be distorted to make the electrostatic holding device as a whole poor in flatness, thus making it impossible to convey the glass substrate while keeping the glass substrate at desired flatness.
[0011] Furthermore, when, with the electrostatic holding device poor in flatness, the electrostatic holding device and the glass substrate are rotated together so that the glass substrate faces downward, the glass substrate, which is expensive, may fall off the electrostatic holding device. When the glass substrate falls to be broken into pieces, the glass pieces scatter in the form of particles to contaminate the interior of the deposition apparatus to make it unavoidable to stop the apparatus, thus inviting a decrease in productivity. Further, even in a case where the glass substrate does not fall off, there has been a risk that uneven deposition (including uneven film thickness), circuit pattern misregistration, or the like may occur, as deposition is executed on the glass substrate that is inferior in flatness.
[0012] The present invention has been made in order to solve the problems mentioned above, and it is an object of the present invention to provide an electrostatic chuck, a glass substrate processing method, and said glass substrate that are intended to prevent falling or the like of a workpiece plate body by reducing the weight of and increasing the strength of a base member and thereby maintaining the flatness of the base member, and to make possible a high-speed and high-quality process on the workpiece plate body.
Solution to Problems
[0013] In order to solve the problems described above, an electrostatic chuck according to claim 1 of the present invention includes: an electrostatic holding layer including a dielectric and a holding electrode, the dielectric having a surface serving as a holding surface on which a workpiece plate body is held, the holding electrode being placed within the dielectric; and a base member of which the electrostatic holding layer is placed on the upper surface, the base member including a lower surface plate, a multicellular structure, and side surface plates, the multicellular structure being constituted by a plurality of polygonal tubular bodies or circular tubular bodies tightly arranged in an upright position on the lower surface plate, the side surface plates covering side surfaces of the multicellular structure, respectively.
[0014] According to this configuration, when the workpiece plate body, such as a glass substrate, is placed on the surface of the electrostatic holding layer and the holding electrode starts to conduct electricity, an electrostatic force induced on the workpiece plate body and the electrostatic hold layer surface causes the workpiece plate body to be held on the electrostatic holding layer surface.
[0015] By supporting the electrostatic chuck with supporting members such as shafts at both edges of the base member in this state, the workpiece plate body can be conveyed together with the electrostatic chuck.
[0016] Incidentally, when the base member of the electrostatic chuck is made of solid heavy aluminum, there is a risk that the base member may be distorted by a large load being applied to the edges of the base member at which the electrostatic chuck is being supported by the shafts.
[0017] In the present invention, however, the base member includes the lower surface plate, a multicellular structure, and side surface plates, the multicellular structure being constituted by a plurality of polygonal tubular bodies or circular tubular bodies tightly arranged on the lower surface plate, the side surface plates covering sides of the multicellular structure, respectively. As such, the base member has a very light and strong structure. Therefore, the electrostatic chuck per se is light.
[0018] For this reason, even in a case where the electrostatic chuck holding the workpiece plate body is conveyed or rotated while being supported by the shafts at both edges of the base member, a load is hardly applied to the edges of the base member at which the electrostatic chuck is being supported by the shafts. Therefore, there is almost no risk that the base member may be distorted.
[0019] In claim 1 of the present invention, an electrostatic chuck according to claim 2 of the present invention is configured such that the multicellular structure is a structure constituted by a plurality of triangular tubular bodies, quadrangular tubular bodies, or hexagonal tubular bodies tightly arranged on the lower surface plate without space left between the tubular bodies.
[0020] This configuration makes it possible to enhance the strength of the base member while maintaining the lightweight properties of the base member.
[0021] In claim 1 or claim 2 of the present invention, an electrostatic chuck according to claim 3 of the present invention is configured such that the electrostatic holding layer is attached directly to an upper surface of the multicellular structure of the base member.
[0022] In any one of claim 1 to claim 3 of the present invention, an electrostatic chuck according to claim 4 of the present invention is configured further include a flow channel extending from a fluid supply port to a fluid discharge port, wherein: the fluid supply port is provided in the lower surface plate of the base member and communicates with a lower opening of at least one of the plurality of polygonal tubular bodies or circular tubular bodies; and the fluid discharge port is provided in the lower surface plate but in a different place from the fluid supply port and communicates with a lower opening of at least one of the plurality of polygonal tubular bodies or circular tubular bodies, the flow channel being formed by providing, in a peripheral wall of the polygonal tubular body or circular tubular body whose lower opening communicates with the fluid supply port, a communication hole through which a fluid from the fluid supply port flows out to an adjacent polygonal tubular body or circular tubular body, by providing, in a peripheral wall of the polygonal tubular body or circular tubular body whose lower opening communicates with the fluid discharge port, a communicating hole through which the fluid flows in from an adjacent polygonal tubular body or circular tubular body, and by providing, in a peripheral wall of each of the other polygonal tubular bodies or circular tubular bodies, one communicating hole through which the fluid flows in from an adjacent polygonal tubular body or circular tubular body and another communicating hole through which the fluid flows out to another adjacent polygonal tubular body or circular tubular body.
[0023] This configuration allows a fluid for use in cooling supplied from the fluid supply port to flow into the polygonal tubular body or circular tubular body whose lower opening communicates with the fluid supply port. Then, the fluid flows out through the communicating hole provided in the peripheral wall of this polygonal tubular body or circular tubular body to an adjacent polygonal tubular body or circular tubular body. After that, the fluid flows from the adjacent polygonal tubular body or circular tubular body into another polygonal tubular body or circular tubular body through one communicating hole, and flows out to another adjacent polygonal tubular body or circular tubular body through another communicating hole. The fluid repeatedly flows into and out of other polygonal tubular bodies or circular tubular bodies. Finally, the fluid flows into the polygonal tubular body or circular tubular body whose lower opening communicates with the fluid discharge port, and is discharged to the outside through the fluid discharge port.
[0024] That is, the electrostatic chuck of the present invention allows the fluid flows through the flow channel extending from the fluid supply port to the fluid discharge port through the plurality of polygonal tubular bodies or circular tubular bodies, thus allowing the electrostatic holding layer on the upper surface of the base member to be cooled by the fluid.
[0025] In claim 4 of the present invention, an electrostatic chuck according to claim 5 of the present invention is configured such that the communicating holes are provided in uppermost parts of the peripheral walls of the respective polygonal tubular bodies or circular tubular bodies.
[0026] This configuration allows the fluid supplied from the fluid supply port to flow from one polygonal tubular body or circular tubular body to another through the communicating holes. At this time, in the presence of air in a polygonal tubular body or circular tubular body, there is a risk that the fluid may push the air toward an upper part of the polygonal tubular body or circular tubular body and the air may stay there. The air, staying in the upper part of the polygonal tubular body or circular tubular body, is present between the electrostatic holding layer and the fluid, thus reducing the cooling action of the fluid on the electrostatic holding layer.
[0027] In the electrostatic chuck of the present invention, however, the communicating holes are provided in uppermost parts of the peripheral walls of the respective polygonal tubular bodies or circular tubular bodies. Therefore, the air staying in the upper part of the polygonal tubular body or circular tubular body is pushed away together with the fluid toward the fluid discharge port through the communicating holes. This prevents the air from staying in the upper part of the polygonal tubular body or circular tubular body, thus making it possible to effectively cool the electrostatic holding layer.
[0028] A glass substrate processing method according to claim 6 of the present invention includes: a first step of holding a glass substrate on a surface of an electrostatic chuck according to any one of claim 1 to claim 52 ; a second step of supporting the electrostatic chuck at both side edges of the base member, with the electrostatic chuck holding the glass substrate; a third step of, while supporting the electrostatic chuck, rotating the entire electrostatic chuck downward so that the glass substrate faces downward; and a fourth step of processing a surface of the glass substrate from a lower position than the glass substrate.
[0029] According to this configuration, executing the first step causes the glass substrate to be held on the surface of the electrostatic chuck, and after that, executing the second step causes the electrostatic chuck to be supported at both side edges of the base member, with the electrostatic chuck holding the glass substrate.
[0030] When the electrostatic chuck is thus supported at both edges of the base member, there is a risk that the base member may be distorted by a large load being applied to the edges of the base member at which the electrostatic chuck is being supported. In the present invention, however, since an electrostatic chuck according to any one of claim 1 to claim 3 of the present invention is used as the electrostatic chuck for holding the glass substrate, the electrostatic chuck per se is very light. For this reason, even when the electrostatic chuck is for example conveyed while being supported by shafts at both edges of the base member, a load is hardly applied, so that there is no risk that the base member may be distorted.
[0031] Then, executing the third step causes the entire electrostatic chuck to be rotated downward so that the glass substrate faces downward, while the electrostatic chuck is being supported.
[0032] Since, at this time, the base member is not distorted and the electrostatic chuck has its flatness maintained at a desired value, the glass substrate does not fall off the electrostatic chuck during rotation. As a result of this, the glass substrate, too, faces downward while keeping the desired flatness.
[0033] Executing the fourth step with the glass substrate facing downward causes a surface of the glass substrate to be processed from a lower position than the glass substrate.
[0034] Since, at this time, the glass substrate is keeping the desired flatness, a process such as deposition can be accurately performed on the glass substrate without the occurrence of uneven deposition (including uneven film thickness), circuit pattern misregistration, or the like.
[0035] A glass substrate according to claim 7 of the present invention is a glass substrate processed by the glass substrate processing method according to claim 6 of the present invention.
Advantageous Effects of Invention
[0036] As described above in detail, the electrostatic chuck according to claim 1 of the present invention is configured such that the base member is lighter in weight and higher in strength. Therefore the base member of the electrostatic chuck is hardly distorted even when the electrostatic chuck is conveyed and rotated while holding the workpiece plate body and being supported by the shafts. This in turn brings about an advantageous effect of keeping the flatness of the base member at the desired value.
[0037] This also makes it possible to reduce the size of and simplify the structure of an apparatus such as a deposition apparatus as a whole.
[0038] Moreover, since the workpiece plate body can be prevented from falling off during rotation of the electrostatic chuck, contamination in the apparatus, stoppage of the apparatus, and the like due to breakage of the workpiece plate body can be prevented.
[0039] Further, since the flatness of the base member is kept at the desired value and flatness of the workpiece plate body is maintained, uneven deposition (including uneven film thickness), circuit pattern misregistration, or the like in a process such as deposition can be prevented.
[0040] Furthermore, the reduction in the weight of the electrostatic chuck 1 per se increases the speed of movement, such as conveyance and rotation, of the workpiece plate body. This in turn brings about an effect of shortening takt time and improving productivity.
[0041] Further, the electrostatic chuck according to claim 2 of the present invention is configured such that the multicellular structure is a structure constituted by a plurality of triangular tubular bodies, quadrangular tubular bodies, or hexagonal tubular bodies tightly arranged on the lower surface plate without space left between the tubular bodies. This configuration brings about an effect of enhancing the strength of the base member while maintaining the lightweight properties of the base member.
[0042] Further, the electrostatic chuck according to claim 3 of the present invention achieves a further reduction in the weight of the electrostatic chuck.
[0043] Furthermore, the electrostatic chuck according to claim 4 or claim 5 of the present invention allows the electrostatic holding layer having been heated to be effectively cooled by the fluid flowing through the polygonal tubular bodies or circular tubular bodies.
[0044] Further, the glass substrate processing method according to claim 6 of the present invention makes it possible to process a glass substrate while keeping the glass substrate at desired flatness, thus bringing about an effect of performing a process such as deposition at a high speed and with accuracy.
[0045] Furthermore, the use of the lightweight electrostatic chuck increases the speed of movement, such as conveyance and rotation, of the glass substrate, thus bringing about an effect of shortening takt time and improving productivity.
[0046] Furthermore, the glass substrate according to claim 7 of the present invention is processed by the glass substrate processing method according to claim 6 of the present invention, thus brining about an effect of providing a high-quality glass substrate free of uneven deposition (including uneven film thickness), circuit pattern misregistration, or the like.
BRIEF DESCRIPTION OF DRAWINGS
[0047] FIG. 1 is an exploded perspective view showing an electrostatic chuck according to a first embodiment of the present invention.
[0048] FIG. 2 is a cross-sectional view of the electrostatic chuck.
[0049] FIG. 3 is an exploded perspective view showing a base member.
[0050] FIG. 4 is a perspective view showing a regular hexagonal tubular body.
[0051] FIG. 5 is a process chart showing the processing of a glass substrate with use of the electrostatic chuck.
[0052] FIG. 6 is a schematic plan view showing a process of supporting the base member with shafts.
[0053] FIG. 7 is a cross-sectional view showing an electrostatic chuck according to a second embodiment of the present invention.
[0054] FIG. 8 is a cross-sectional view showing an electrostatic chuck according to a third embodiment of the present invention.
[0055] FIG. 9 is a schematic plan view for explaining a communicating hole in each regular hexagonal tubular body.
[0056] FIG. 10 is a cross-sectional view showing the flow of a fluid.
[0057] FIG. 11 is a schematic plan view showing the flow of the fluid.
[0058] FIG. 12 is a perspective view showing modifications of tubular bodies.
DESCRIPTION OF EMBODIMENTS
[0059] Best modes of the present invention are described below with reference to the drawings.
First Embodiment
[0060] FIG. 1 is an exploded perspective view showing an electrostatic chuck according to a first embodiment of the present invention. FIG. 2 is a cross-sectional view of the electrostatic chuck.
[0061] As shown in FIGS. 1 and 2 , an electrostatic chuck 1 of the present embodiment includes a base member 2 and an electrostatic holding layer 3 .
[0062] FIG. 3 is an exploded perspective view showing the base member 2 . FIG. 4 is a perspective view showing a regular hexagonal tubular body.
[0063] As shown in FIG. 3 , the base member 2 is a box object formed by a lower surface plate 20 , side surface plates 21 to 24 , and an upper surface plate 25 . The base member 2 has a multicellular structure 4 inside it. The multicellular structure 4 is constituted by regular hexagonal tubular bodies 40 .
[0064] As shown in FIG. 4 , each of the regular hexagonal tubular bodies 40 is a regular hexagonal tubular body having openings at both the upper and lower ends thereof.
[0065] As shown in FIG. 3 , the multicellular structure 4 is a honeycomb structure constituted by such regular hexagonal tubular bodies 40 tightly arranged in an upright position on the lower surface plate 20 without space left between the regular hexagonal tubular bodies 40 .
[0066] The four side surface plates 21 to 24 hermetically cover side surfaces of the multicellular structure 4 , i.e. the honeycomb structure. The single upper surface plate 25 hermetically covers an upper surface of the multicellular structure 4 .
[0067] In the present embodiment, the multicellular structure 4 , the lower surface plate 20 , on which the multicellular structure 4 is mounted, the side surface plates 21 to 24 , and the upper surface plate 25 are made of aluminum subjected to Al 2 O 3 anodic oxide coating (alumite treatment).
[0068] However, the base member 2 may of course be made of a material other than aluminum, such as SUS, iron, copper, titanium, a ceramic (including ALN, SiC, Al 2 O 3 , SiN, zirconium, BN, TiC, and TiN), or the like.
[0069] In the present embodiment, coating with an insulator film is done by alumite treatment. However, for example, the entire base member 2 may be filmed by thermal spraying of a ceramic such as Al 2 O 3 , and insulation may be achieved by another insulator film.
[0070] In FIG. 1 , the electrostatic holding layer 3 is a component configured to hold a large-size glass substrate W that is a workpiece plate body. As shown in FIG. 2 , the electrostatic holding layer 3 is bonded to an upper surface of the base member 2 with an adhesive 30 .
[0071] Specifically, the electrostatic holding layer 3 is completely bonded to the upper surface of the base member 2 by applying the adhesive 30 to either the upper surface plate (and the side surface plates 21 to 24 ) of the base member 2 or a lower surface of the electrostatic holding layer 3 and then curing the adhesive 30 through the application of heat.
[0072] The adhesive 30 used in the present embodiment is a thermosetting adhesive. Alternatively, the electrostatic holding layer 3 can also be bonded to the base member 2 by using an ultraviolet curable adhesive as the adhesive 30 .
[0073] As shown in FIG. 1 , the electrostatic holding layer 3 includes a dielectric 31 and a holding electrode 32 .
[0074] The dielectric 31 is a dielectric having a surface serving as a holding surface on which the glass substrate W is held, and contains the holding electrode 32 .
[0075] As shown in FIG. 2 , the holding electrode 32 , placed within the dielectric 31 , is connected to a direct-current power supply 33 , and is configured to conduct electricity when a switch 34 is turned on.
[0076] In the present embodiment, the dielectric 31 is formed by a polyimide film such as Kapton (registered trademark). Further, the holding electrode 32 is made of carbon ink, Cu, or the like. Instead of being made of any of these materials, however, the holding electrode 32 may be made of a conductive substance (in foil or paste form) composed mostly of or mixed with SUS, iron, nickel, silver, platinum, or the like.
[0077] Alternatively, it is possible to use a ceramic as a dielectric and, by using a metal plate with the ceramic film, constitute the electrostatic holding layer 3 including the dielectric 31 and the holding electrode 32 .
[0078] Furthermore, as shown in FIGS. 1 and 2 , the present embodiment shows a electrode of coulomb force-type as an example of the holding electrode 32 . However, the holding electrode 32 may be a comb-like electrode of gradient force-type to have a higher holding force with respect to a nonconductor such as glass.
[0079] Next, an example of use of the electrostatic chuck of the present embodiment is described below.
[0080] It should be noted that this example of use is one in which a glass substrate processing method of the present invention is specifically executed.
[0081] FIG. 5 is a process chart showing the processing of a glass substrate with use of the electrostatic chuck. FIG. 6 is a schematic plan view showing a process of supporting the base member with shafts.
[0082] First, when the glass substrate W is placed on a surface of the electrostatic holding layer 3 as shown in (a) of FIG. 5 and the switch 34 shown in FIG. 2 is turned on, the direct-current power supply 33 applies a voltage to the holding electrode 32 , so that the holding electrode 32 starts to conduct electricity. This induces an electrostatic force on the glass substrate W and the electrostatic hold layer 3 . The electrostatic force thus induced causes the glass substrate W to be held on the surface of the electrostatic holding layer 3 (execution of a first step).
[0083] (a) of FIG. 5 and (a) of FIG. 6 show bifurcated shafts 100 of a deposition apparatus (not illustrated). The shafts 100 have their leading ends configured to be inserted into holes 2 a provided at both edges of the base member 2 .
[0084] With the glass substrate W held on the surface of the electrostatic holding layer 3 , as shown in (b) of FIG. 5 and (b) of FIG. 6 , the glass substrate W can be conveyed together with the electrostatic chuck 1 by inserting the shafts 100 into the holes 2 a at both edges of the base member 2 and supporting the electrostatic chuck 1 with the shafts 100 (execution of a second step).
[0085] When the electrostatic chuck 1 is thus supported by the shafts 100 at both edges of the base member 2 , there is a risk that the base member 2 may be distorted by a large load being applied to the edges of the base member 2 at which the electrostatic chuck 1 is being supported by the shafts 100 .
[0086] In the electrostatic chuck 1 of the present embodiment, however, the base member 2 has its inner part constituted by the multicellular structure 4 and, what is more, the multicellular structure 4 is a honeycomb structure constituted by the regular hexagonal tubular bodies 40 tightly arranged in an upright position on the lower surface plate 20 without space left between the regular hexagonal tubular bodies 40 , and is therefore very light in weight and also high in strength against transverse pressure and longitudinal pressure.
[0087] For this reason, even when the base member 2 is supported by the shafts 100 at both edges, a load is hardly applied to the base member 2 and the base member 2 is therefore not distorted.
[0088] Then, as shown in (c) of FIG. 5 , the shafts 100 are rotated while supporting the electrostatic chuck 1 . This causes the electrostatic chuck 1 as a whole to face downward so that the glass substrate W is located on the lower side (execution of a third step).
[0089] Since, at this time, the base member 2 is not distorted and the electrostatic chuck 1 has its flatness maintained at a desired value as described above, the glass substrate W is being firmly held on the electrostatic holding layer 3 . For this reason, the glass substrate does not fall off the electrostatic chuck 1 . That is, the glass substrate is facing downward while keeping the desired flatness.
[0090] While the glass substrate W is facing downward, as shown in (d) of FIG. 5 , a deposition process is performed on the glass substrate W by allowing the electrostatic chuck 1 to pass directly above a deposition source 110 while being supported by the shafts 100 (execution of a fourth step).
[0091] Specifically, with a mask 120 formed into a circuit pattern or the like and placed directly below the glass substrate W, a deposition material 111 is sprayed from the deposition source 110 toward the glass substrate W being held by the electrostatic chuck 1 .
[0092] Since, at this time, the glass substrate W is keeping the desired flatness, the deposition process can be accurately performed on the glass substrate W without the occurrence of uneven deposition (including uneven film thickness), circuit pattern misregistration, or the like.
[0093] In the electrostatic chuck 1 of the present embodiment, as described above, the base member 2 has a lightweight and robust structure. Therefore, the base member 2 is not distorted by a load applied to the base member 2 , and has its flatness maintained at a desired value. This in turn makes it possible to prevent breakage of the glass substrate W, contamination of the ambient environment, and the like, and to reduce the size of and simplify the structure of an apparatus such as a deposition apparatus as a whole.
[0094] Furthermore, the reduction in the weight of the electrostatic chuck 1 per se increases the speed of movement, such as conveyance and rotation, of the glass substrate W. This in turn shortens takt time and improves productivity.
Second Embodiment
[0095] Next, a second embodiment of the present invention is described below.
[0096] FIG. 7 is a cross-sectional view showing an electrostatic chuck according to a second embodiment of the present invention.
[0097] In an electrostatic chuck 1 ′ of the present embodiment, as shown in FIG. 7 , the base member 2 is constituted by the lower surface plate 20 , the side surface plates 21 to 24 , and the multicellular structure 4 , with the omission of the upper surface plate 25 .
[0098] The electrostatic holding layer 3 , which is made of a ceramic, is attached directly to an upper surface of the multicellular structure 4 of the base member 2 , which has no upper surface plate 25 , with the adhesive 30 .
[0099] The omission of the upper surface plate 25 as a component of the base member 2 reduces the number of members, thus further reducing the weight and cost of the electrostatic chuck.
[0100] The other components, functions, and effects are the same as those of the first embodiment, and as such, are not described here.
Third Embodiment
[0101] Next, a third embodiment of the present invention is described below.
[0102] FIG. 8 is a cross-sectional view showing an electrostatic chuck according to a third embodiment of the present invention. FIG. 9 is a schematic plan view for explaining a communicating hole in each regular hexagonal tubular body.
[0103] As shown in FIG. 8 , an electrostatic chuck 1 ″ of the present embodiment includes a flow channel 5 formed inside the multicellular structure 4 .
[0104] The flow channel 5 is a flow channel through which a fluid for use in cooling flows. The flow channel 5 extends from a fluid supply port 50 to fluid discharge ports 51 and 52 through the multicellular structure 4 .
[0105] Specifically, the fluid supply port 50 is provided in a central part of the lower surface plate 20 of the base member 2 , and communicates with a lower opening 40 a - 1 of a regular hexagonal tubular body 40 - 1 located in the center.
[0106] Moreover, the fluid discharge ports 51 and 52 are provided in both corners of the lower surface plate 20 , and communicate with lower openings 40 a - 2 and 40 a - 3 of regular hexagonal tubular body 40 - 2 and 40 - 3 located in both corners, respectively.
[0107] The regular hexagonal tubular body 40 - 1 , which communicates with the fluid supply port 50 , has a pair of communicating holes 61 and 62 .
[0108] As shown in FIG. 9 , the communicating holes 61 and 62 are provided in the uppermost part of a peripheral wall 40 b - 1 of the regular hexagonal tubular body 40 - 1 , and allow a fluid L from the fluid supply port 50 to flow out to adjacent regular hexagonal tubular bodies 40 through the communicating holes 61 and 62 , respectively.
[0109] The regular hexagonal tubular body 40 - 2 ( 40 - 3 ), which communicates with the fluid discharge port 51 ( 51 ), has a single communicating hole 63 ( 64 ).
[0110] The communicating hole 63 ( 64 ) is provided in the uppermost part of a peripheral wall 40 b - 2 ( 40 b - 3 ) of the regular hexagonal tubular body 40 - 2 ( 40 - 3 ), and allows a fluid L from an adjacent regular hexagonal tubular body 40 to flow into the regular hexagonal tubular body 40 - 2 ( 40 - 3 ) through the communicating hole 63 ( 64 ).
[0111] Each of the regular hexagonal tubular bodies 40 - n other than the regular hexagonal tubular bodies 40 - 1 to 40 - 3 has a pair of communicating holes 65 and 66 .
[0112] The communicating holes 65 and 66 are provided in the uppermost part of a peripheral wall 40 b - n of each of the regular hexagonal tubular bodies 40 - n . The communicating hole 65 is a communicating hole through which a fluid L from an adjacent regular hexagonal tubular body 40 - n −1 flows in. The communicating hole 66 is a communicating hole through which the fluid L flows out to an adjacent regular hexagonal tubular body 40 - n +1. It should be noted that in FIG. 9 , each of the regular hexagonal tubular bodies 40 adjacent to the regular hexagonal tubular bodies 40 - 1 to 40 - 3 shall be deemed to be a given regular hexagonal tubular body 40 - n.
[0113] Next, the functions and effects of the electrostatic chuck F′ of the present embodiments are described below.
[0114] FIG. 10 is a cross-sectional view showing the flow of a fluid L. FIG. 11 is a schematic plan view showing the flow of the fluid L.
[0115] As indicated by arrows in FIG. 10 , the fluid L, such as cooling water or coolant gas, when supplied from the fluid supply port 50 to the regular hexagonal tubular body 40 - 1 of the multicellular structure 4 , flows out to the adjacent regular hexagonal tubular bodies 40 through the communicating holes 61 and 62 of the regular hexagonal tubular body 40 - 1 , respectively.
[0116] After that, the fluid L reaches the fluid discharge port 51 ( 52 ) through the communicating holes in a large number of regular hexagonal tubular bodies 40 . That is, the fluid L flows from an adjacent regular hexagonal tubular body 40 - n −1 through the communicating hole 65 into a given regular hexagonal tubular body 40 - n and flows out to an adjacent regular hexagonal tubular body 40 - n +1 through the communicating hole 66 . Then, finally, the fluid L reaches the regular hexagonal tubular body 40 - 2 ( 40 - 3 ), and is discharged out of the base member 2 through the fluid discharge port 51 ( 52 ).
[0117] That is, as shown in FIG. 11 , the fluid L reaches the fluid discharge port 51 ( 52 ) through almost all of the regular hexagonal tubular bodies 40 from the fluid supply port 50 , thus effectively cooling the electrostatic holding layer 3 (see FIG. 10 ) placed over the top of the lower surface plate 20 .
[0118] Incidentally, in the presence of air in a regular hexagonal tubular body 40 , the fluid L pushes the air toward an upper part of the regular hexagonal tubular body 40 and the air stays there. This causes the air to be present between the electrostatic holding layer 3 and the fluid L, thus posing a risk of reducing the cooling action on the electrostatic holding layer 3 .
[0119] To avoid the risk, the present embodiment, as shown in FIG. 8 , provides the communicating holes 61 to 66 in the uppermost parts of the peripheral walls of the respective regular hexagonal tubular bodies 40 so that the air can be pushed away toward the fluid discharge port 51 ( 52 ) through the communicating holes 61 to 66 .
[0120] Therefore, in a case where air does not stay in the upper part of a regular hexagonal tubular body 40 or in a case where air stays in the upper part of a regular hexagonal tubular body 40 but does not affect the cooling of the electrostatic holding layer 3 , the communicating holes 61 to 66 do not need to be provided in the uppermost parts of the peripheral walls of the regular hexagonal tubular bodies 40 . In this case, for example, the communicating holes 61 to 66 may of course be provided in the central parts or lowermost parts of the peripheral walls.
[0121] The other components, functions, and effects are the same as those of the first and second embodiments, and as such, are not described here.
[0122] The present invention is not limited to the embodiments described above, but may be altered or modified in various ways within the scope of the gist of the present invention.
[0123] For example, while, in each of the embodiments described above, the multicellular structure 4 is a honeycomb structure, a multicellular structure needs only be constituted by a plurality of polygonal tubular bodies or circular tubular bodies tightly arranged on the lower surface plate 20 of the base member 2 , and is not limited to a honeycomb structure. Therefore, a multicellular structure constituted by a plurality of non-hexagonal polygonal tubular bodies or circular tubular bodies 41 (see (a) of FIG. 12 ) tightly arranged in a honeycomb manner is also encompassed in the scope of the present invention.
[0124] However, it is preferable that a multicellular structure be such a structure as to be robust over transverse pressure and longitudinal pressure and be able to contribute to a reduction in weight.
[0125] From this standpoint, a tight arrangement of tubular bodies other than triangular, quadrangular, or hexagonal tubular bodies in a honeycomb manner has space left between adjacent tubular bodies, and as such, is inferior in strength to the multicellular structure 4 of the present invention, which is a honeycomb structure. Therefore, it is most preferable, in terms of strength, that a multicellular structure be constituted by a plurality of regular triangular tubular bodies 42 (see (b) of FIG. 12 ), regular quadrangular tubular bodies 43 (see (c) of FIG. 12 ), or regular hexagonal tubular bodies 40 (see each of the embodiments described above) tightly arranged without space left between the tubular bodies.
[0126] While the third embodiment has been described above by taking, as example, a case where one or two communicating holes is/are provided in the peripheral wall of each regular hexagonal tubular body 40 , any number of communicating holes may be provided. That is, since the number of regular hexagonal tubular bodies 40 adjacent to a single regular hexagonal tubular body 40 is six, three or more communicating holes may be provided in the single regular hexagonal tubular body 40 so that the single regular hexagonal tubular body 40 can communicate with three or more of the six adjacent regular hexagonal tubular bodies 40 .
REFERENCE SIGNS LIST
[0000]
1 , 1 ′, 1 ″ . . . electrostatic chuck,
2 . . . base member,
3 . . . electrostatic holding layer,
4 . . . multicellular structure,
5 . . . flow channel,
20 . . . lower surface plate,
21 to 24 . . . side surface plate,
25 . . . upper surface plate,
30 . . . adhesive,
31 . . . dielectric,
32 . . . holding electrode,
33 . . . direct-current power supply,
34 . . . switch,
40 , 40 - 1 to 40 - n +1 . . . regular hexagonal tubular body,
40 a - 1 to 40 a - 3 . . . lower opening,
40 b - 1 to 40 b - n . . . peripheral wall,
41 . . . circular tubular body,
42 . . . regular triangular tubular body,
43 . . . regular quadrangular tubular body,
50 . . . fluid supply port,
51 , 52 . . . fluid discharge port,
61 to 66 . . . communicating hole,
100 . . . shaft,
110 . . . deposition source,
111 . . . deposition material,
120 . . . mask,
L . . . fluid,
W . . . glass substrate.
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An electrostatic chuck that enables high speed and high quality processing of a plate to be processed, and in which the weight of a base member is reduced and the strength thereof increased so as to maintain the flatness of the base member and prevent the plate to be processed from falling; a glass substrate processing method; and said glass substrate. An electrostatic chuck ( 1 ) provided with a base member ( 2 ) and an electrostatic suction layer ( 3 ). The base member ( 2 ) is formed by a lower-surface plate ( 20 ), side-surface plates ( 21 - 24 ), and an upper-surface plate ( 25 ), and has a part ( 4 ) for a plurality of individual structures configured therein. The part ( 4 ) for a plurality of individual structures has a honeycomb structure that is caused by regular hexagonal tubes ( 40 ) and enables the weight of the base member ( 2 ) to be reduced and the strength thereof increased.
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BACKGROUND OF THE INVENTION
This invention has as its object the provision of a liquid cooler which is particularly suitable for the cooling of semiconductor power elements.
Up to now liquid coolers have been used rather seldom for the cooling of semiconductor power elements because cooling semiconductor power elements with relatively low power losses by air has been substantially simpler. However, with increasing heat losses of such semiconductor power elements, the dimensions of air coolers has increased so that now cooling arrangements employing air as the cooling medium are very much larger than arrangements employing a liquid as the cooling medium.
Designers of cooling arrangements for semiconductor power elements are now starting to use liquids as the cooling medium, since liquid cooling media have a much higher heat absorbing capacity than air, and in addition, meet with safety requirements as to shock and transient conditions because their heat inertia can absorb short heat impulses with only a small increase in temperature.
Liquid cooling also substantially reduces the noise level which inherently accompanies air cooled arrangements, since with liquid cooling it is possible to reduce or even completely to eliminate noise by disposing the heat exchanger and the necessary pumps outside the space in which the semiconductor power element is located. These advantages, however, are somewhat reduced by the complexity of cooling systems which employ liquid cooling media and the requirement for their maintenance, both of which result in increased operating costs. Despite such complications liquid cooling with forced circulation of the cooling medium holds out much promise for the cooling of semiconductor power elements.
Known liquid coolers are usually designed with straight liquid conducting channels, mainly because of their simple manufacturing technology. Such coolers are usually formed of material having good heat conductivity, such as for example copper. However, laminar layers are formed on the walls of such straight channels, thereby reducing the heat transfer from the body of the cooler to the cooling medium. There are also known arrangements of liquid coolers (U.S. Pat. No. 3,823,771) wherein a circular plate with radial grooves is fitted on at least one said thereof to a flat connecting piece provided with concentric circular grooves for the supply of cooling liquid. These arrangements are simple from the technological viewpoint; however, because of insufficient turbulence of the cooling liquid during its passage through the cooler they do not provide the required cooling effect for the space which is provided for the cooler in certain applications.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a liquid cooler for semiconductor power elements which to a high degree eliminates the creation of a laminar layer in the cooling space, is easy to manufacture, and can be adapted to use under different conditions.
In a preferred embodiment of liquid cooler in accordance with the invention, there is employed a relatively thick base plate of copper or the like having a plurality of spaced parallel channels open on a first broad surface thereof and closed in the second broad surface thereof. The parallel walls bounding the channels are divided into aligned studs spaced longitudinally of the channels. The studs have opposite parallel flanks which are parallel to the channels, whereas the two remaining opposite surfaces of the studs in each row thereof are formed as parts of cylindrical surfaces, the confronting surfaces of successive studs in each row being oppositely concave and mirror images of each other. The base is inserted into and secured and sealed to a round cup-shaped housing having a broad bottom (or top) which closes the open sides of the channels, and annular sidewall which closely surrounds the base plate. The ungrooved second surface of the base plate forms a bearing surface for the cooled semiconductor element. The cooling studs, the outer ends of which engage the inner surface of the broad bottom of the housing, stiffen the cooler and absorb a large part of the thrust exerted between the semiconductor power element and its clamping support.
The liquid cooler according to the invention provides a high turbulence of the flowing cooling liquid and thus a higher coefficient of heat transfer from the cooling medium to the material of the cooler. Due to the small space required by the cooler a good utilization of the material of the cooler is achieved, which is made, for example, of copper which is both expensive and increasingly difficult to obtain. Other advantages of the liquid cooler according to the invention are its high cooling effect, and the simple manufacturing technology required for its manufacture. Thus the cooler may be made by a number of conventional steps including boring, turning and cutting, and also dye casting. Thus the cooler can be made, if desired, by an automatic manufacturing process.
DESCRIPTION OF DRAWINGS
An examplary embodiment of a liquid cooler made in accordance with the invention is illustrated in the attached drawings, in which:
FIG. 1 is a view of the illustrative liquid cooler partially in plan and partially in horizontal section;
FIG. 2 is a view of the cooler of FIG. 1 partially in side elevation and partially in vertical section the section being taken along the line 2--2 of FIG. 1.;
FIG. 3 is a schematic view in side elevation of an arrangement including a semiconductor power element clamped between two liquid coolers made in accordance with the embodiment of FIGS. 1 and 2; and
FIG. 4 is a view similar to FIG. 3 of a modified embodiment of the semiconductor power element of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
The liquid cooler 14 shown in the drawings comprises a main body 2 in the form of a thick cylindrical disc made, for example, of copper or the like, member 2 closely fitting within a round open-topped (FIG. 2) cup-shaped housing 1, which may also be made of copper or the like. The upstanding annular side walls of the housing closely embrace the outer edge of the body 2, the upper circumferential edge of the body 2 being secured and sealed to the upper inner edge of the side wall of the housing throughout their circumferences, as indicated at 10, as by soldering, welding, forming in the cold state, or by glueing. The lower broad surface of the body 2 is secured to the upper broad surface of the bottom portion of the housing by a layer of solder of suitable adhesive 11.
As shown in FIGS. 1 and 2 the body 2 is provided with a plurality of spaced parallel slots 5 which extend laterally across the body and from the bottom of the body (FIG. 2) upwardly to near the upper broad surface thereof. The upstanding portions of body 2 between slots 5 are divided into a plurality of upstanding studs 6 by a plurality of laterally spaced bores 7 having a diameter somewhat in excess of the thickness of the studs 6, the bores having their axes on the laterally extending center line of the studs. It will thus be seen that the studs have parallel opposite sides or flanks 19 and that the curved ends 20 of successive studs in a row are in the form of portions of a circular cylinder and are mirror images of each other.
The slots 5 and the bores 7 communicate with each other and form spaces for the reception of a cooling liquid. Cooling liquid is introduced into the cooler through an inlet fitting 3 and is exhausted therefrom through an outlet fitting 4. To insure the systematic flow of the cooling liquid through all of the slots 5 and bores 7 there is provided an upstanding diametrically disposed partition 8 which extends from and is sealed to the bottom of the housing 1 (FIG. 2) and the lower upstanding wall of the housing as shown in FIG. 1. The partition ends somewhat short of the upper portion of the upstanding side wall of the housing as shown in FIG. 1 to provide a passage 12 between the end of the partition and the upstanding side wall of the housing 1 at such location. Thus liquid flows into the cooler through the inlet fitting 3, fills and flows through all of the slots 5 and bores 7 therein to the left of the partition (FIG. 1), flows through the passage 12, fills and flows through the slots 5 and the bores 7 to the right of the partition, and outwardly through the outlet fitting 4.
The body 2 of the cooler is made of material of good heat conductivity, for example copper, aluminum or the like. The housing 1 can be made of metal; it can however also be made of some insulating material, for instance of plastic material. If the housing 1 and the base 2 are made of copper, as above described it is advantageous to connect them by a layer of solder 11, for example a silver solder containing 72% silver, remainder copper. The housing 1 and the base 2 can be made of aluminum or magnesium, or of their alloys, and in that case their surfaces are provided with a protective coating of the chromate type.
The length and width of cross section of the studs 6 is advantageously made to have the ratio of 2:1. The studs 6 in the body 2 may be made for example by a coordinate boring machine and by a subsequent cutting or milling, so that the cooling spaces 5, 7 are created between the studs 6, as above described. It is also possible to make the studs 6 by dye casting. The compact external surface of the body 2 is provided with a centering opening 9 for accurately locating the cooled semiconductive elements bearing on such surface.
In the embodiment of FIG. 2 the upper and lower surfaces of the semiconductor power element are flat and ungrooved.
In the embodiment of FIG. 4 wherein parts similar to those in FIG. 2 are designated by the same reference characters, the upper and the lower surfaces of the element are provided with spaces 22 and 21, respectively, for a metal which at operating temperatures of the cooled semiconductive element is in liquid condition. Such storage spaces may be made for example in the shape of grooves or scratches which allow the creation of a layer of such metal having a thickness between 0.01 to 2 mm. such metal consists for example of an alloy of bismuth, copper, lead, tin and cadmium with a melting point of 70° C., alloys which are generally suitable are those with 48 to 55% of bismuth, 18 to 40% lead, 2 to 15% tin, and 0 to 10% cadmium, such percentages being by weight. Alloys having no cadmium can comprise 10 to 21% of indium. These alloys are eutectic, have low melting point, and have a small change of volume in the course of transition from the solid to the liquid phase. It is also possible to use non-eutectic alloys of bismuth, lead, tin and cadmium, namely those which melt within a certain temperature range which is within the range of operating temperature of the cooled semiconductor element. These alloys can contain 35 to 51% bismuth, 27 to 37% of lead, 9 to 20% of tin, and 3 to 10% of cadmium, all percentages being by weight.
The cooling medium, for example water, enters the cooler by way of the inlet fitting 3 into the cooling space 5, 7 of the body 2 where it strikes the flanks 19 of the cooling studs 6, is whirled into vortices, such turbulent liquid then flowing around the partition wall 8 and through the passage 12, finally leaving the cooler by way of the outlet fitting 4. The highly turbulent flow of the cooling liquid, provided by the described shape of the cooling studs 6 and by their geometrical arrangement in the body 2 prevents the formation of any laminar layers of the liquid along the walls of the cooling space 5, 7 and produces an increase in the rate of heat transfer from the material of the cooler to the cooling liquid.
As will be seen in FIG. 1, the bores 7 between the studs 6 in successive rows of studs are staggered, so that the axes of the bores in each row thereof are disposed midway of the lengths of the studs in the next adjacent rows of studs. Further, each of the axes of the passages through the inlet and outlet fittings lies at a very substantial angle with respect to the lengths of the flanks 19 of the studs 6. These two factors cause a turbulent flow of liquid through the cooler, and insure the scouring of the surfaces of the studs 6 by the flowing liquid to prevent laminar flow of liquid along the surfaces thereof. Further, the oppositely curved surfaces 20 on the studs 6 cause a change in the speed of flow of the liquid as it first passes between the first opposite, more closely confronting edges of successive studs 6, into the relatively wider space 7, and out of such space 7 through the second opposite more closely confronting edges of successive studs 6. As the liquid leaves spaces 7, the curved surfaces 20 divert it to create two streams which are directed in opposite directions generally along the flanks 19 of the next adjacent studs. The flowing together of such two streams further adds to the turbulence of flow of cooling liquid through the cooler.
In FIG. 3 there is schematically shown one possible application of the cooler of the invention. There a semiconductor power element 15 is shown clamped between two opposed liquid coolers 14 in accordance with the invention by means of an upper clamping member 16 and a lower clamping member 17 which are forcibly urged toward each other by means not shown. It is to be understood that in some instances only one cooler 14 is required, the semiconductor power element 14 then being clamped between one liquid cooler 14 and one of clamping elements 16, 17.
The liquid cooler in accordance with the invention, due to its substantially more perfect removal of heat losses from a member such as a semiconductor power element to be cooled, permits a substantial increase of the current load of the semiconductor element, and thus widens the range of possibilities of application of the semiconductor element. The cooler of the invention thus permits an increase in the power loads of semiconductor power elements and thus leads directly by its use to the achievement of substantial savings in electric power. The versatility of the electric cooler according to the invention particularly adapts it for use in the field of power electronics and in other applications wherein the transmission of large amounts of power gives rise to very substantial quantities of heat.
Although the invention is illustrated and described with reference to one preferred embodiment thereof, it is to be expressly understood that it is in no way limited to the disclosure of such a preferred embodiment, but is capable of numerous modifications within the scope of the appended claims.
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There is disclosed a liquid cooler for semiconductor power elements, the cooler having an external surface for bearing against the cooled element. The internal space of the cooler is formed so as to generate a whirling motion of the cooling medium supplied thereto.
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TECHNICAL FIELD
This invention relates to thin-profile battery electrode connection members, button-type battery electrode connection members, thin-profile battery constructions, button-type battery constructions, and methods of establishing electrical connections with and between both thin-profile batteries and button-type batteries.
BACKGROUND OF THE INVENTION
Thin-profile batteries are characterized by having thickness dimensions which are less than a maximum linear dimension of its anode or cathode. One type of thin-profile battery is a button-type battery. Such batteries, because of their compact size, permit electronic devices to be built which themselves are very small or compact. When a higher voltage is needed in such devices, the batteries can be stacked or cascaded with one another to achieve a series electrical connection. When the electrical devices with which such batteries are used are small in dimension, it is desirable to configure one or more of the batteries in such a way as to conserve or minimize the space requirements necessary to achieve a desirable electrical connection between the batteries and other components of the device.
This invention arose out of concerns associated with improving the structures and methods through which thin-profile or button-type batteries are interconnected with one another and with electrical devices.
SUMMARY OF THE INVENTION
Thin-profile battery electrode connection members, button-type battery electrode connection members, thin-profile battery constructions, button-type battery constructions, and methods of establishing electrical connections with and between both thin-profile batteries and button-type batteries are described. In one implementation, an electrode connection member comprises an inner conductive surface, and outer peripheral conductive surface, and an intermediate conductive surface joined with and extending between the inner and outer surfaces. The connection member defines an internal volume which is sized to receive at least one thin-profile battery. In one aspect, the intermediate conductive surface tapers between the inner and outer surfaces. The taper enables more than one thin-profile battery to be mounted within the internal volume without the need for edge insulation material over one of the batteries to prevent grounding. The electrode connection member can be mounted on a substrate for providing a generally self-contained, space-conserving power source which can include more than one battery connected in a series electrical connection.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is a side sectional view of an electrode connection member formed in accordance with one aspect of the invention.
FIG. 2 is a top plan view of the FIG. 1 electrode connection member.
FIG. 3 is a side sectional view of an electrode connection member formed in accordance with another aspect of the invention.
FIG. 4 is a side sectional view of the FIG. 1 electrode connection member within which a thin-profile battery is received.
FIG. 5 is a side sectional view of an electrode connection member which is formed in accordance with another aspect of the invention and within which two thin-profile batteries are received.
FIG. 6 is a view of the FIG. 4 electrode connection member mounted on a substrate.
FIG. 7 is a view of the FIG. 5 electrode connection member mounted on a substrate.
FIG. 8 is a view of an exemplary electronic device which incorporates an electrode connection member and battery stack in accordance with the invention.
FIG. 9 is a view which is taken along line 9--9 in FIG. 1.
FIG. 10 is a view which is taken along line 10--10 in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).
Referring to FIGS. 1, 2, 9, and 10, a connection member or container is shown generally at 20 and is configured for use with at least one thin-profile or button-type battery. Connection member 20 can comprise any suitable conductive material such as nickel foil, stainless steel sheet, metal screen mesh, and the like, and can be formed by stamping, etching, drawing, or molding any of such materials. Connection member 20 includes an inner conductive electrode connection surface 22 which is sized to receive and form an electrical connection with a battery electrode surface as will become apparent below. A battery electrode surface is mounted over or atop surface 22 and can be fixed in place with conductive epoxy. Accordingly, surface 22 can be considered as a mounting surface. At least a portion of surface 22 is generally planar and is oriented within a mounting surface plane P 1 . Connection surface 22 has an outermost boundary edge 24 which is generally circular in shape.
A conductive side or intermediate surface 26 is provided and is joined with connection surface 22 proximate outermost boundary edge 24. The outermost boundary edge defines a joinder location between surfaces 22, 26, with both surfaces extending generally away therefrom. In the illustrated example, surface 26 tapers to extend generally outwardly from connection surface 22 and define a generally frustum-shaped side surface.
An outer peripheral conductive surface or rim 28 is provided and is joined with side surface 26 proximate a joinder location 30. Outer surface or rim 28 defines an opening into an internal volume 32 which is defined by connection surface 22 and side surface 26. Internal volume 32 is sized to receive a substantial portion of at least one thin-profile or button-type battery. Side surface 26 tapers generally outwardly from joinder location 24 toward joinder location 30. The rim defines a terminus of side surface 26. Outer surface 28 is oriented within a plane P 2 which is generally parallel with plane P 1 . Side surface 26 includes at least a portion which extends away from plane P 1 at an angle θ which is generally oblique relative thereto. Other angles θ are of course possible. In the illustrated example, a substantial portion of side surface 26 extends away at the angle θ. Surface 26 is dimensioned to achieve substantial alignment between outer surface 28 and a battery electrode surface of a thin-profile or button-type battery which is received within connection member 20.
In one aspect, connection member 20 has a thickness dimension t adjacent inner conductive surface 22 and in a direction A which is normal to plane P 1 . Outer surface or rim 28 includes first and second boundary edges 34, 36 respectively, which have a minimum separation distance d therebetween. First and second boundary edges 34, 36 are generally circular in shape and concentric with one another. In the illustrated example, minimum separation distance d is greater than the thickness dimension t of connection member 20.
FIG. 3 shows a connection member 20 which is similar in construction to the FIG. 1 connection member except that outer surface or rim 28 defines a minimum separation distance d which is approximately equal to thickness dimension t.
FIGS. 9 and 10 illustrate different cuts which are taken through connection member 20 of FIG. 1. FIG. 9 shows a first portion or cut comprising side surface 26 which is taken through line 9--9 in FIG. 1. FIG. 10 shows a second portion or cut comprising side surface 26 which is taken through line 10--10 in FIG. 1. The side surface portions bound respective first and second areas inside surface 26 and within internal volume 32 which lie in respective first and second planes. The first and second planes are spaced from one another and the areas defined therewithin are different from one another. In the illustrated example, the first and second planes are generally parallel with one another and with plane P 1 . The first plane (FIG. 9) is disposed closer to connection surface 22 than the second plane (FIG. 10). In the illustrated example, the first area is less than the second area.
Referring to FIG. 4, an exemplary thin-profile battery comprising a button-type battery 38 is placed or mounted on connection member 20 and received within internal volume 32. Battery 38 includes a pair of terminal housing members which define a pair of outwardly-facing electrodes 40, 42. Electrode 40 comprises the lid or anode electrode of the battery and electrode 42 comprises the can or cathode electrode of the battery. Side surface 26 is dimensioned to achieve substantial alignment of outer surface 28 and electrode surface 40. Such is observed as plane P 2 is seen to be generally coincident with surface 40. Electrode 42 is conductively received against surface 22 and accordingly establishes electrical communication between electrode surface 42 and connection member 20. Accordingly, a single battery is provided and comprises different respective surfaces with which electrical connection is made with connection member 20, and substantial alignment is achieved with outer surface 28. Conductive adhesion with epoxy or other suitable bonding techniques such as welding can be utilized to fixedly mount battery 38 within connection member 20, if desired.
Referring to FIG. 5, a connection member which is formed in accordance with an alternate embodiment of the present invention is shown generally at 20a. Like numerals from the above-described embodiment are utilized where appropriate, with differences being indicated by the suffix "a" or with different numerals. Accordingly, mounting surface 22a and side surface 26a define an internal volume 32a which is sized to receive substantial portions of two thin-profile batteries 44, 46. For purposes of the ongoing discussion, battery 44 comprises a first battery and battery 46 comprises a second battery. The batteries are oriented in a stack, one atop the other, and can be conductively bonded together if desired. Battery 44 includes a pair of terminal housing members comprising lid and can terminals. The lid and can terminals respectively define a pair of outwardly-facing battery electrode surfaces 48, 50. Battery 46 includes a pair of terminal housing members comprising lid and can terminals. The lid and can terminals respectively define a pair of outwardly facing battery electrode surfaces 52, 54. Side surface 26a is dimensioned to achieve substantial alignment of outer surface 28a and battery electrode surface 52. Accordingly, substantial alignment is achieved with an electrode surface of a different battery from which desired electrical connection is made with connection surface 22a.
Side surface 26a of connection member 20a extends away from connection surface 22a sufficiently to bring at least a portion of the side surface into abutting physical engagement with only one of the batteries received within internal volume 32a. In the illustrated example, such abutting engagement is achieved with battery 44 only and not with battery 46 by imparting a desired degree of taper to side surface 26a. The illustrated side surface 26a is generally frustum-shaped which is similar to the one-battery embodiment of FIG. 4. By virtue of the angularity of side surface 26a relative to surface 22a, no electrical insulation is necessary to protect battery 46 from undesirably grounding against the side surface. Such insulation can, however, be provided if desired.
FIGS. 6 and 7 show a substrate portion 56 having a generally planar substrate surface 58. The substrate can comprise a printed circuit substrate, i.e. printed circuit board, or a flexible circuit board and the like. A pair of spaced electrical contacts or contact pads 60, 62 are supported by substrate 56. Contact 60 comprises two different spaced portions which are each laterally spaced from contact 62. Exemplary materials for the contact pads include screen- or stencil-printed conductive materials such as copper or conductive printed thick film (PTF). The material from which contacts 60, 62 are formed can be either recessed within substrate 56 or disposed atop the substrate. In the context of this document, both constructions are seen to provide a generally planar outer surface adjacent which one or more batteries can be mounted or received.
Outer surfaces or rims 28 (FIG. 6), 28a (FIG. 7) are disposed against substrate surface 58. Surface 58 substantially encloses the battery or batteries received within the respective internal volumes 32, 32a. Accordingly, containers 20, 20a and substrate surface 58 define respective enclosures 64, 64a inside of which a battery or batteries are received. Electrode surfaces 40 (FIG. 6), 52 (FIG. 7) are conductively received against contact pad 62, while outer surfaces 28, 28a are conductively received against contact pad 60. Outer surfaces 28, 28a can be conductively bonded to the contact pads by conductive epoxy. Accordingly an electrical circuit connection is formed.
Referring to FIG. 7, batteries 44, 46 are conductively connected together in a stack which defines a series electrical connection. A first electrical connection is defined between electrode surface 48 of battery 44 and electrode surface 54 of battery 46. Such electrical connection can arise from a mere physical engagement of the batteries or through the application of a suitable conductive epoxy material or other bonding agent to effectively conductively bond the two together. A second electrical connection is provided between electrode surface 50 of battery 44 and electrode surface 52 of battery 46. In the illustrated example, the second electrical connection is provided through the respective contact pads which operably connect with circuitry which is external to the batteries. An exemplary arrangement is shown in FIG. 8 where a single integrated circuitry chip 66 is mounted over substrate 56. Connection member 20a is received over the substrate and operably mounted thereon so that the batteries are placed into electrical communication with chip 66. The contact pads are defined by conductive traces which form, together with chip 66, the second electrical connection mentioned above. In the illustrated and preferred embodiment, chip 66 is configured for wireless radio frequency communication. An exemplary chip is described is U.S. patent application Ser. No. 08/705,043, which names James O'Toole, John R. Tuttle, Mark E. Tuttle, Tyler Lowrey, Kevin Devereaux, George Pax, Brian Higgins, Shu-Sun Yu, David Ovard and Robert Rotzoll as inventors, which was filed on Aug. 29, 1996, is assigned to the assignee of this patent application, and is fully incorporated herein by reference.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
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Thin-profile battery electrode connection members, button-type battery electrode connection members, thin-profile battery constructions, button-type battery constructions, and methods of establishing electrical connections with and between both thin-profile batteries and button-type batteries are described. In one implementation, an electrode connection member comprises an inner conductive surface, and outer peripheral conductive surface, and an intermediate conductive surface joined with and extending between the inner and outer surfaces. The connection member defines an internal volume which is sized to receive at least one thin-profile battery. In one aspect, the intermediate conductive surface tapers between the inner and outer surfaces. The taper enables more than one thin-profile battery to be mounted within the internal volume without the need for edge insulation material over one of the batteries to prevent grounding. The electrode connection member can be mounted on a substrate for providing a generally self-contained, space-conserving power source which can include more than one battery connected in a series electrical connection.
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FIELD OF THE INVENTION
The invention relates to a method of analyzing an example of a starch-containing product. The invention also relates to a device for such analyses.
STATE OF THE ART
It is well known that starch with the addition of fluid, often water, thickens during heating and then thins out with continued heating as a consequence of that the enzyme alpha-amylas converts the starch. Depending on the amount and strength of this enzyme and the resistance of the starch to the enzyme, various degrees of conversion of the starch or alpha-amylas activity are obtained under predetermined conditions.
A well-established, quick and reliable method for the determination of alpha-amylas activity has for many years been the drop number method. In accordance with this method a special apparatus is used, where a precision test tube containing a suspension of a precise sample amount of the actual starch-containing product in a precise amount of distilled water is placed in a boiling waterbath, whereafter agitating of the sample takes place for a certain time with a special agitator, which after finished agitating is allowed to drop, and the time it takes for the agitator to fall a precise distance is measured. The total time in seconds, from that the test tube has been placed in the waterbath and until the agitator after finished agitating has fallen a predetermined distance, defines a drop number value, which consequently forms a measure of the degree of alpha-amylas activity in the actual sample. The drop number value consequently varies according to the properties of the sample.
For e.g. wheat samples the drop number value can vary between approx. 62, which indicates a high degree of alpha-amylas activity, and approx. 400, which indicates a low alpha-amylas activity. For rye samples the drop number interval is less, approx. 62 to approx. 200, with the same proportions between the amount of samples and the amount of water.
During the baking of bread from wheat resp. rye it has been shown that certain drop number values are instructive for predicting the baking result in connection with the processes which are usually used in the western world for baking. For wheat, a drop number of approx. 250 is considered to define a flour which gives a good baked product. Lower drop numbers tend to give a sticky bread crumb while higher drop numbers, e.g. over 400, gives a dry crumb and also a smaller bread volume.
The drop number method is today an established standard method for the branch organizations around the world for the determination of alpha-amylas activity. Generally for this method, the drop number apparatus, which is manufactured by the company Perten Instruments AB, Huddinge, Sweden, is used
The usability of the drop number method is amongst other things dependent on the fact that the temperature profile during testing has been shown to have a large correspondence with the temperature profile in bread during baking, at least in the critical region of 60°-90° C. Experience has, however, shown that the drop number does not give exhaustive information on the properties of a raw material, but two raw materials with the same drop number can have different properties in varying respects.
It is also previously known to use different methods for determining how the viscosity of a water suspension of a sample changes when the suspension is heated up and then allowed to cool. In such a standard method according to Brabender (Amylograph) the suspension is heated up from 25° C. to 95° C. with an even rate of temperature increase and with constant agitating. When the temperature of 95° C. is obtained, the temperature is held at this value for 30 minutes (first holding period) with continued agitating. Thereafter the suspension is cooled to 50° C. at a certain rate and then held at this temperature for 30 minutes (second holding period). The agitation resistance, i.e. the torque, herewith gives a measure of the viscosity. Here one has, however, been especially interested in certain places on a curve which gives viscosity as a function of time. First and foremost, one has looked at the initially obtained peak value of the viscosity, but also the viscosity value when reaching 95° C. has been of interest Then one has been interested in the viscosity value at the end of the first holding period, when the temperature is still 95° C. Another viscosity value of interest has been the point where the temperature has dropped to 50° C., and finally at the end of the second holding period, i.e. after 30 minutes at 50° C. This method is time-demanding and is aimed at giving the viscosity values at special stages of the testing at special temperatures.
In the modem food industry the requirement is growing for, in a simple and reliable way, to be able to determine the properties of a raw material so that e.g. it becomes easy to select the right raw material for a certain product which can be made according to a special process, in order to obtain an even and good quality for the product. There is a corresponding requirement for being able to sort different raw materials for suitable processes.
The named methods have deficiencies in this respect, wherefore it is desirable with simple means to be able to bring forth better methods for determining the properties, especially with respect to the starch and enzyme properties, of different starch-containing products.
OBJECT OF THE INVENTION
The object of the invention is to make it possible to simply obtain refined and clear information about the properties of the starch and the influence of the alpha-amylas enzyme in the starch in a temperature region which is important for the starch. The object is also to produce a reliable device which makes it possible to perform the desired analysis.
DESCRIPTION OF THE INVENTION
A proposed method in accordance with the invention to perform the analysis is stated below. Advantageous variants of this method are also disclosed. By studying the changes of the viscosity of the sample during heating, a property profile is obtained for the sample with respect to its heating properties and by comparing this property profile with at least on corresponding predetermined property profile, it is possible to more closely determine the nature of these properties. It has been shown to be especially rewarding to study the viscosity changes as a function of the temperature in the sample. In this way a picture is obtained of how the sample behaves in a manufacturing process.
In accordance with the invention it has been shown that an excellent device for analysis is obtained through modifying a known falling numbers apparatus. This solution furthermore offers the extremely large advantage that the apparatus obtained can still be used for falling number determination, wherein a more complete analysis of a sample can be made than that which was previously possible.
DESCRIPTION OF THE FIGURES
The invention is explained in more detail in the following with the help of the accompanying drawings, which show examples of embodiments, where:
FIG. 1 shows schematically a device for analyzing during agitating, made in accordance with the invention,
FIG. 2 shows the device in FIG. 1 but when the agitator has been allowed to fall a certain distance,
FIG. 3 shows the construction principle of the control system of the device in FIGS. 1 and 2, and
FIGS. 4-9 show viscosity changes as a function of the temperature in the sample for a number of different starch-containing raw materials.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows an analysis device 1 according to the invention, where a falling number apparatus of conventional type is modified in order to permit viscosity measuring and temperature measuring in a water suspension of a starch-containing product during analysis. Falling number apparatuses of different models have been marketed for many years by Perten Instruments AB in Huddinge, Sweden, and are well known to the person skilled in the art. The construction of the equipment will therefore only be described to the extent which is necessary in order to understand the invention.
On a stand 2 there is a container 3 with a temperature-regulated waterbath 4 in which a test tube 5 is lowered. The test tube 5 contains a water suspension 6 of a starch-containing product which is to be analyzed. Lowered into the test tube 5 and the water suspension 6 is an agitator 7 , the upper end of which rests in a holder 8 with the help of which the agitator 7 can be moved up and down in the test tube in the direction of the double arrow 9 . On the stand 2 there is also a motor 10 , which via a mechanism 11 and a power sensor 12 can set the holder 8 in movement up and down at a speed which can vary through changing the rotational speed of the motor. In the lower end of the agitator 7 there is a temperature sensor 13 for sensing the actual temperature in the contents of the test tube 5 .
FIG. 2 shows how the agitator 7 after finishing agitating has been released by the holder 8 and falls into the test tube 5 . A position sensor 14 indicates when the agitator 7 has reached an intended lower position. A conductor 15 passing through the agitator 7 connects the temperature sensor 13 with a measuring unit.
From FIG. 3 is evident how the control system for the analysis device 1 in FIGS. 1 and 2 is constructed. The power sensor 12 and the temperature sensor 13 are each via their own measurement amplifier 16 connected to a control unit 17 where signal processing occurs. The position sensor 14 is directly connected to this control unit 17 . A revolution sensor 18 for the motor 10 and a temperature sensor 19 for the waterbath 4 are each connected via their own control amplifier 20 to the control unit 17 , which in turn is connected to a computer 21 for checking and the presentation of falling numbers and alternative curves for e.g. power/time, temperature/time and power/temperature.
The power sensor 12 can advantageously be a strain gauge sensor or some other type of sensor, e.g. of optical or piezoelectrical type, which is placed at a suit-able place on the holder 8 in order to measure its deformation during agitating. This deformation, can through calibration, be made to represent a certain resistance to motion or viscosity in the contents of the test tube. With the help of the control unit 17 it is possible to change the rotational speed of the motor 10 , and in this way the up and down movements per time unit which the agitator 7 can perform. It is also possible with the help of the control unit 17 to control the temperature in the water-bath 4 to different temperatures in the region 60° C.-100° C. in order to obtain different measuring conditions. Normally, however, the temperature in the waterbath is held at 100° C.
Testing in accordance with the invention normally takes place in the following way. A precise, ground amount of the raw material which is to be tested is mixed through shaking with a precise amount of distilled water in the test tube 5, which thereafter is placed in the holder 3 and its waterbath 4 , the temperature of which is 100° C. After five seconds the agitating begins automatically and continues while the contents of the test tube heat up. During the heating up, the viscosity changes are registered as a function of the temperature in the sample. A number of such results are shown in FIGS. 4-9, where the viscosity is given in units related to the equipment used.
FIG. 4 shows a comparison between two different sorts of flour, where curve A represents the first type of flour and the curve B the second type of flour. In both cases the mixing relationship was 7 g/25 ml, i.e. 7 g of flour were mixed with 25 ml of distilled water. The temperature of the waterbath 4 was 100° C., and the stroke frequency for the agitator 7 was 2 Hz.
The flour A has a viscosity maximum of 57.3 units at the temperature 80.1° C., while the corresponding value for the flour B is 45.5 units at 67.5° C. The viscosity quotient between the flours A and B is consequently 57.3/45.5=1.26, and the difference in temperature between the two viscosity maxima of the two curves , which have completely different profiles, is 12.6° C.
Conventional flour data for the flours A and B is the following:
Flour A
Flour B
Viscosity maximum
1050 AE at 89.3° C.
215 AE at 68.9° C.
based on Amylogram
Drop number
360
179
Ash content, %
0.56
1.12
Protein content, %
13.2
12.4
Water content, %
15.0
13.0
Gluten, %
28.3
—
Gluten index
84
—
As is evident according to the invention a considerably larger correspondence between the maximum viscosity levels is obtained than with conventional methodology.
FIG. 5 shows tests with the flour A in two different mixing relationships. For the upper curve A the mixing relationship is 7 g/25 ml, i.e. the same as in FIG. 4, while for the lower curve A 2 the mixing relationship is only half as big, i.e. 3.5 g/25 ml. As is evident, for the lower mixing relationship considerably lower viscosity values are obtained. The curve A 1 gives a viscosity maximum of 57.3 units at 80.1° C. while the corresponding value for the curve A 2 is 10.2 units at 86.4° C. The viscosity maximum consequently drops and is shifted towards a higher temperature at lower mixing relationships. The curves A 1 and A 2 have substantially different profiles.
The waterbath temperature and the agitating frequency were the same as in FIG. 4 .
FIG. 6 shows, for the flour A, how the viscosity varies as a function of temperature at different stroke frequencies for the agitator at a waterbath temperature of 100° C. and a mixing relationship of 7 g/25 ml.
The curves A 11 , A 12 , A 13 and A 14 each represent a stroke frequency of 2.85, 2.0, 1.25 and 1.0 Hz for the agitator. The curve A 11 has a viscosity maximum of 58.1 units at 80.1° C. Corresponding values are for A 12 55.1 units at 78.6° C., for A 13 38.8 units at 79.0° C., and for A 14 32.6 units at 77.7° C. The viscosity maximum is consequently shifted towards a lower value and a lower temperature with increasing agitator frequency.
FIG. 7 shows tests with three different flours C, D and E from Germany, according to corresponding curves. The curve C gives a viscosity maximum of 56.8 units at 65.9° C. while the corresponding values for curve D are 42.1 units at 62.7° C. and for curve E 32.4 units at 61.3° C.
Conventional flour data for the flours C, D and E are the following:
Flour C
Flour D
Flour E
Viscosity maximum
675 AE
375 AE
185 AE
based on Amylogram
at 69.5° C.
at 63.0° C.
at 60.0° C.
Drop number
254
127
62
Water content, %
13.3
12.8
12.4
The mixing relationship was 6.8 g/25 ml for all of them. Temperature of the waterbath 100° C. and the agitator frequency 2 Hz.
According to conventional flour data, as is evident, halving the drop number leads to approximately halving of the viscosity maximum. According to tests performed now, however, the quotient between the viscosity maxima is the following: C/D =1.35 and D/E=1.30. The three different flour types consequently each gave their own special curve profile which indicates different properties.
FIG. 8 shows tests with four different Swedish flours F, G, H and I with falling numbers in the interval 230 - 292 . As is evident, the curves F, G, H and I lie extremely close to each other and are difficult to separate. The viscosity maximum lies for all of them at approximately 44 units at a temperature of approx. 76° C. In all tests thickening begins at approx. 65° C. The test conditions are the same as in FIG. 6 .
FIG. 9 shows tests with an Austalian flour according to curve J and a Spanish flour according to curve K. Curve J gives a viscosity maximum of 58.7 units at 73.2° C. and the corresponding value for curve K is 55.5 units at 85.0° C. The same test conditions as in FIGS. 7 and 8. The flour J had a falling number of 700 and a water content of 11.7%. The corresponding values for the flour K were 540 and 12.2%.
Despite the large difference in drop number for the two flours, according to the curves in FIG. 9, similar maximum levels for the viscosity were achieved for the two flours but at clearly different temperatures.
As is evident above, in the different tests, result curves are obtained where not only the position for the maximum viscosity varies but also the general profile of the curves has different appearances. A comparison between e.g. FIGS. 4 and 7 shows that the viscosity change in the beginning is more abrupt in FIG. 4 than in FIG. 7 and subsequently is considerably steeper and more constant than in FIG. 7 . Curve A has a rather wide peak while the other curves have a narrow peak, and drop more slowly after the maximum than curve A. It is on the basis hereof obvious that the starch in the different samples behaves differently, i.e. the raw materials in the different samples have different properties. This means that a certain curve profile indicates certain properties while another curve profile indicates other properties. This consequently makes it possible to distinguish different raw materials with respect to starch properties, either in certain sections along the curve or with respect to the whole curve. In order to more closely be able to determine the meaning of a certain curve, it is suitable to perform a comparison with a corresponding curve for a predetermined sample.
On the basis of a so obtained analysis of the starch properties of the raw material, it is possible to determine the best method of using the raw material in question, i.e. each raw material can more easily be used in the best way.
Through the selected testing method a uniform and reproducible heat transfer to the sample from the surrounding waterbath is obtained. A large advantage is also that conventional falling number measuring can take place with the same conditions concerning temperature change and agitator frequency. This increases the reliability of the analysis, as several properties can be related to each other.
A consequence of the uniform heat transfer is also that the temperature increase takes place at an even rate, and therefore the temperature scale on the basis hereof in principle can be replaced by a time scale, after suitable calibration. Instead of measuring temperature with a temperature sensor it is consequently possible, on the basis of a calculation algorithm and suitable base parameters, to obtain a temperature value.
In a comparison between different test curves the curve slope at different positions is of great interest. It can, for example, be suitable to characterize a product through stating an average slope, before or after maximum, between two points, e.g. points representing 25% and 75% of the viscosity maximum, or other suitable values. It can also be of interest, for example, to define the width of the maximum viscosity as a temperature interval between two points on the curve representing e.g. 85% of the maximum viscosity. As is evident, a large number of definitions can be selected, depending on requirements and desires.
In manufacturing processes where heating takes place, e.g. in baking, it is of great interest to know how the properties of the starch change during heating and thereby can influence the intended result. By performing an analysis according to the invention, it will be possible, more reliably than previously, to be able to select the right raw material for a certain process and vice versa, as knowledge of the raw material and the process can be improved.
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A suspension of a starch-containing product in heated during agitation, whereby the viscosity is registered as a function of the temperature. A curve over the relationship between viscosity an temperature is treated as a property profile for the sample and is compared with another known curve in order to determine the heating properties for the sample. A device for this analysis has an agitator ( 7 ), the drive means ( 10, 11 ) of which has a power sensor ( 12 ) for sensing the power which the agitator is subjected to during the agitating, whereby a measure of the viscosity is obtained. A temperature sensor ( 13 ) senses the temperature of the sample.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional Patent Application No. 60/589,044, filed Jul. 19, 2004, the disclosure of which is incorporated herein by reference,
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to devices, systems and methods for assisting blood flow, and, particularly, to blood pumps that include a moving (for example, an oscillating) valve assembly to propel blood. The pumps of the present invention can be either fully implanted or temporarily connected to the circulation using percutaneous blood conduits. The pumps of the present invention can, for example, be fully or completely implanted for months to years to alleviate or correct heart failure and related symptoms.
[0003] Heart failure, or the inability of the heart to pump sufficient blood for the body's needs, results in very poor quality of life, huge costs to society, and hundreds of thousands of yearly deaths. Heart failure is caused by an abnormally low cardiac output. Cardiac output is the out flow of blood from the heart and is measured in liters of blood flow per minute or I/min. Cardiac output for a normal man at rest or during light activity is around 5 liters per minute. Severe heart failure exists when the cardiac output is as low as 2.5 to 3.5 liters per minute. For an average man in heart failure with a heart rate of 80 beats per minute, the average amount of blood that is pumped with each heartbeat or stroke volume might be 37 milliliters or ml. The same man with a normal heart might pump 62 milliliters with each heartbeat. An ideal treatment for heart failure would boost the low 37 ml stroke volume up to the normal 62 ml stroke volume.
[0004] The main pumping chamber of the heart or left ventricle, LV has an inlet mitral valve and an outlet aortic valve. During left ventricular contraction or systole, the inlet valve closes as blood is pushed through the aortic valve into the aorta or main artery to the body. When the LV is resting during diastole, LV pressure may be between 2 and 20 mm of Hg pressure. This diastolic pressure is termed the LV preload and the preload will be in the higher end of its pressure range during heart failure. During active LV contraction or systole, the LV must eject its blood against the pressure in the aorta. Aortic pressure is typically between 70 and 140 mm Hg Pressure. This aortic pressure is termed the after-load. It is well known that, if the after-load is reduced in heart failure, the LV stroke volume will naturally increase and this increase is one reason that afterload-reducing drugs such as ACE-inhibitors help heart failure patients.
[0005] Blood pumps which lower the aortic pressure after-load are attractive because they allow the failing LV to eject more blood with less effort. However, no after-load reducing devices have thus far been shown to be practical for indefinitely supporting the failing LV. Instead, all long term (that is, months to years), commercially available heart assist devices, whether rotary turbine pumps or collapsing chamber pumps go around or bypass the failing LV, pumping blood from the LV apex through the pump into the aorta. By doing so, they act in parallel to the LV and essentially compete with the LV in their pumping action. This pumping competition has several negative complications including right heart failure, fusion of the aortic valve over time and the risk of collapsing the LV. Collapsing chamber pumps are physically large and cannot be implanted in some small patient because of their size. Rotary turbine pumps are attractively small, but have other limiting complications. For example, the rotary turbine pumps induce high levels of shear stress in the blood elements and also may reduce the normal pulsatility of the blood entering the aorta. The effect of the high shear stress on the blood cells is to promote blood clotting which can lead to strokes and heart attacks. Physicians try to reduce this blood clotting by giving the patients anticoagulants and this, in turn, puts the patients at risk of excessive bleeding. These clotting and bleeding complications are substantial limitations to broader use of rotary turbine assist pumps.
[0006] For short-term heart assist (that is, hours to days), a common method of providing cardiac assist is the use of counterpulsation devices such as intraaortic balloon pumps or IABPs. IABPs provide an afterload-reducing type of assist. As described in U.S. Pat. Nos. 4,733,652 and 3,692,018 by Kantrowitz et al. and Goetz et al., the main benefit of such devices stems from after-load reduction of the left ventricle during systole and providing increased diastolic pressure for perfusing the coronary and other arteries during diastole. Typical patients needing this type of treatment suffer from cardiogenic shock or need perioperative circulatory support. The nature of IABP design restricts itself to acute use only, since the bulky balloon drive mechanism remains outside the patient's body necessitating patient confinement to a hospital bed.
[0007] A “dynamic aortic patch” is disclosed in U.S. Pat. No. 4,051,840, to Kantrowitz et al. and is in clinical trials. It is surgically and permanently attached to the patients descending aorta and is pneumatically activated by an external air pump. Such a pump lowers the LV after-load, facilitating left ventricular contraction and increasing stroke volume.
[0008] Pouch-type auxiliary ventricles attached to the patient's aorta have been described. These devices use mechanical or pneumatic means for the pumping the blood contained in the pouch and are disclosed in U.S. Pat. Nos. 3,553,736 and 4,034,742 by Kantrowitz et. al. and Thoma. Some of these devices have a single access port to the aorta that serves as both the inlet and the outlet for blood flow. Single port designs have the disadvantage of recirculation and relative flow stagnation, increasing the risk of clot formation and thromboembolism. Others have both inlet and outlet ports to the aorta and are typically connected in parallel with the aorta. See, for example, U.S. Pat. Nos. 4,195,623 and 4,245,622 by Zeff et al. and Hutchins et al.
[0009] U.S. Pat. Nos. 5,676,162, 5,676,651, and 5,722,930, by Larson et al., describe a single stroke moving valve pump designed for ascending aortic placement. The Larson device uses a commercially available artificial heart valve with attached magnets and requires excision of a portion of the aorta. A series of separate electric coils step the valve/magnet combination forward in a sliding action within a cylinder. The device is quite large for the limited space available between the heart and the take-off vessels from the aorta to the upper body and brain. The device is designed to have one stroke in synchronization with each LV systole. The blood volume required for closing commercially available heart valves is typically 2-5 ml and therefore multiple smaller oscillations per heart contraction would suffer from volumetric inefficiency. Another problem with the Larson device is the tight crevice between the cylinder wall and the moving valve. This tight space results in high blood shear and the resultant risk of blood clotting complications. The same problem exists with a moving valve pump described by Child, U.S. Pat. No. 4,210,409. The Child pump has two valves, one stationary and one moving.
[0010] Thornton, U.S. Pat. No. 5,147,281 discloses an oscillatory valve blood pump that is external to the body and fits in an enclosure the size of a briefcase. It uses a stationary coil to attract a magnetic tube encasing a one-way valve. Its forward stroke propels blood until the tube assembly stops and is repelled backward by return leaf springs that were charged during the forward stroke. A second stationary valve is sometimes in the circuit. A stretchable silicone rubber tube connects the tube or pipe-valve assembly with the pumps inlet and outlet.
[0011] Nitta, in ASAIO Transactions 1991:37: M240-M241 describes a “univalved artificial heart” powered electro-magnetically wherein the valve oscillates within the frequency range of 1 to 30 Hz. The valve is contained in a tube, with attached magnetic material. Stationary electric coils actuate the tube-magnet-valve combination. The valve is described as a jellyfish valve. One problem with jellyfish valves is the compound curvature or wrinkling of the membrane that occurs when the valve opens and closes. One can liken the action of the jellyfish valve to that of an umbrella that oscillates between a circular flat membrane and a wrinkled umbrella shape as it closes and opens. Wrinkling of the membrane is virtually impossible to prevent in a jellyfish valve and introduces stresses and strains that significantly limit the life of the valve.
[0012] Hashimoto, U.S. Pat. No. 5,266,012, also uses a jellyfish valve in a vibrating pipe blood pump intended for use outside the body. The purpose of this invention is to make the vibrating tube pump portion separable from the drive mechanism so that the blood-contacting portion of the pump can be disposable.
[0013] Although numerous pharmacologic, biologic, and mechanical interventions have been devised to address heart disease/failure (some of which are described above), heart failure remains a major public health problem with an estimated five million victims in the United States alone. It is, therefore, very desirable to develop improved devices, systems and methods of assisting the heart in pumping blood through the circulatory system.
SUMMARY OF THE INVENTION
[0014] In one aspect, the present invention provides pump, which can, for example, be partially or fully implantable within a patient, for assisting blood flow. The pump includes a flexible conduit, at least one valve attached to the flexible conduit about the perimeter of the valve; and a drive mechanism to move the valve to pump blood within the conduit. The drive mechanism can, for example, be adapted to complete a single stroke during each heart ventricle contraction and/or to complete multiple strokes (that is, oscillate) during a single contraction.
[0015] The flexible conduit can be generally linear or can be arced. When the conduit is arced, the drive mechanism is preferably adapted to move (for example, oscillate) the valve on an arced path. The valve can, for example, be in operative connection with a pivot arm which is in operative connection with the drive mechanism.
[0016] A wide variety of drive mechanisms can be used in the pumps of the present invention. For example, the drive mechanism can include a brushless direct current electric motor. The drive mechanism can further include a speed reduction mechanism in operative connection with/between the brushless direct current motor and the valve. In one embodiment, the speed reduction mechanism includes a gear system (for example, one or more sets of planetary gears in operative connection with a sun gear).
[0017] In another embodiment, the drive mechanism includes an electromagnetic motor including at least one magnetically conductive plate. The magnetically conductive plate can be curved to effect movement of the valve in an arcuate path. The electromagnetic motor can further include at least one movable coil. The at least one moveable coil can, for example, include aluminum wiring.
[0018] In another embodiment, the drive mechanism includes at least one hydraulic pump.
[0019] The pump preferably further includes a control mechanism in operative connection with the drive mechanism. The control mechanism can, for example, be adapted to actuate the drive mechanism during systole and, preferably, in the later half of systole.
[0020] In one embodiment, the valve includes a plurality of openings or valve ports (which can be formed separately in a valve frame). Each of the plurality of openings has a closure mechanism (or valve) in operative connection therewith. Each closure mechanism is operable to at least partially close (preferably substantially or completely close) the opening to which it is operatively connected when the moveable valve is moved forward and to open the opening to which it is operatively connected when the valve is moved rearward. Each of the closure mechanisms can, for example, include a flap of resilient material. In this embodiment, each of the flaps is preferably placed in operative connection with the corresponding opening so that the resilient material of the flap flexes without complex curvature. In one embodiment, each of the openings comprises at least one generally linear side and the flap is attached to the generally linear side. Each of the openings can be angled with respect to the direction of flow, thereby reducing the volume of fluid required to be displaced to close each of the closure mechanisms.
[0021] The pump can further include a housing encompassing at least a portion of the flexible conduit. In one embodiment, pressure within the housing outside of the flexible conduit is maintained to be generally the same as pressure within the flexible conduit. For example, a fluid can be contained within the housing outside of the fluid conduit. The pressure of the fluid can be maintained at generally the same pressure as a pressure within the flexible conduit. In general, the volume of the fluid outside the fluid conduit can be chosen so that it equals the volume within the housing outside of the fluid conduit when the fluid conduit is in an unstressed (unpressurized) state.
[0022] The pump can further include an inflow conduit in fluid connection with a first, inflow end of the flexible conduit. The inflow conduit is adapted to be placed in fluid connection with a blood vessel. The pump further includes an outflow conduit in operative connection with a second, outflow end of the flexible conduit. The outflow conduit is adapted to be placed in fluid connection with the blood vessel. In one embodiment, the inflow conduit and the outflow conduit are further adapted to place the pump in series connection with the blood vessel via a single cut in the blood vessel without removing a section of the blood vessel. The single cut in the blood vessel can, for example, be a dissecting cut of the blood vessel, creating a first section of the blood vessel remaining in fluid connection with the heart and a second section of the blood vessel which is no longer in fluid connection with the heart. The inflow conduit in this embodiment is adapted to be placed in fluid connection with the first section of the blood vessel, and the outflow conduit is adapted to be placed in fluid connection with the second section of the blood vessel. Each of the inflow conduit and the outflow conduit can, for example, be flexible. The direction of flow or lines of flow in the inflow conduit and outflow conduit can “cross” so that the inlet of the inlet conduit and the outlet of the outlet conduit can be placed in close proximity to each other with respect to the length of the blood vessel (for example, within 0 to 2 cm of each other. The inflow conduit and the outflow conduit can also be in fluid connection with a flow device that is insertable within a single longitudinal cut in the blood vessel.
[0023] In another aspect, the present invention provides an implantable pump for assisting blood flow, including: a flexible conduit formed in an arc; at least one valve attached to the conduit about the perimeter of the valve; and a drive mechanism to move the valve in an arced path to pump blood within the conduit.
[0024] In a further aspect, the present invention provides an implantable pump for assisting blood flow, including: a flexible conduit; an extending arm; a drive mechanism in operative connection with the extending arm to move the extending arm; and at least one movable valve in operative connection with the extending arm. Movement of the valve is operable to cause flow of blood through the flexible conduit. The extending arm can, for example, move the valve in an arcuate path. In one embodiment, the extending arm pivots about a pivot point. The valve can, for example, be attached to the flexible conduit about the perimeter of the valve.
[0025] In a further aspect, the present invention provides a pump including a conduit and at least one moveable valve within the conduit. The moveable valve includes a plurality of openings. Each of the plurality of openings has a closure mechanism in operative connection therewith. Each closure mechanism is operable to at least partially close the opening to which it is operatively connected when the moveable valve is moved forward and to open the opening to which it is operatively connected when the valve is move rearward. The pump further includes a drive mechanism to move the valve to pump blood within the conduit. In one embodiment, each closure mechanism includes a flap of resilient material.
[0026] In another aspect, the present invention provides an implantable pump for assisting blood flow, including: a conduit; at least one moveable valve within the conduit; and a drive mechanism to move the at least one valve to pump blood within the conduit. The drive mechanism includes an electromagnetic motor including at least one moveable coil in operative connection with the at least one valve via, for example, an extending member.
[0027] In one embodiment, the electromagnetic motor is generally linear and is operative to move the valve along a generally linear path. In another embodiment, the electromagnetic motor is arcuate and is operable to move the valve along a generally arcuate path. In one embodiment, the at least one moveable coil of the electromagnetic motor includes aluminum wiring.
[0028] In another aspect, the present invention provides a method of assisting blood flow including the steps of: effecting a single cut in a blood vessel without removing a section of the blood vessel; and connecting an inflow conduit and an outflow conduit of a pump in connection with the blood vessel via the single cut so that the pump is in serial connection with the blood vessel. In one embodiment, the single cut in the blood vessel is a dissecting cut of the blood vessel, creating a first section of the blood vessel remaining in fluid connection with heart and a second section of the blood vessel which is no longer in fluid connection with the heart. In this embodiment, the step of connecting the inflow conduit and the outflow conduit includes the steps of connecting the inlet conduit to the first section of the blood vessel and connecting the outflow conduit to the second section of the blood vessel. In another embodiment, the single cut in the blood vessel is a longitudinal cut and the inflow conduit and the outflow conduit are in fluid connection with a flow device that is inserted within the blood vessel via the longitudinal cut. The blood vessel can, for example, be the aorta or the pulmonary artery. In many cases, the blood vessel is the ascending aorta to assist a failing left ventricle.
[0029] In a further aspect, the present invention provides a method of assisting blood flow including the steps of: placing a pumping mechanism in serial connection with a blood vessel (for example, the ascending aorta); and actuating the pumping mechanism only in the second half of systole.
[0030] In still a further aspect, the present invention provides an implantable pump for assisting blood flow, including: a flexible conduit; at least one moveable valve to effect blood flow within the conduit; a drive mechanism to move the valve to pump blood within the conduit; and a housing surrounding at least a portion of the flexible conduit. The valve is positioned within the conduit. The housing has a fluid therein which surrounds the flexible conduit and operates to equalize a pressure within the housing outside of the conduit to the pressure within the conduit. The moveable valve can, for example, be attached to the flexible conduit about the perimeter of the valve.
[0031] A primary purpose of the devices, systems and methods of the present invention is to allow a heart failure patient to regain a normal cardiac output and therefore a normal life. Heart failure patients typically have a weakened and dilated left ventricle or LV. During LV contraction in heart failure, the heart squeezes out a limited amount of blood and then stalls for a period of time unable to complete its full ejection of blood. During this stall period, the LV maintains pressure near the aortic pressure level but since no blood is being ejected, no useful work is being performed. It is at this time, later in systole that one, two or more strokes of the valve pumps of the present invention described herein can supplement the heart's stroke or ejected volume to reach a normal level. Since the LV pressure is near that of the aorta in the latter half of systole, the assist pump work is considerably less than if the pressure difference was that between the aorta and the LV during its resting time or diastole. This strategic pump timing allows the pump motors of the present invention to be much smaller than they would otherwise have to be.
[0032] Another purpose of the invention is to be capable of full implantation and be attachable to, for example, the ascending aorta without interfering with coronary artery bypass grafts that are typically attached to this ascending aortic location. Hundreds of thousands of heart failure patients have such grafts. Preferably, the inflow and outflow conduits of the pumps of the present invention can place the pumps of the present invention in serial connection with the aorta via a single cut to the aorta and without removal of any section of the aorta. To facilitate this objective, in one embodiment the flow conduit of the pump of the present invention is curved approximately 180 degrees or more so that its conduits can be readily attached to the severed ends of a blood vessel such as the aorta without excising any aortic section and its possibly connected coronary artery bypass grafts. The curved nature of the pumps of the present invention distinguishes such pumps from other moving valve pumps, which function in a linear fashion.
[0033] It is also preferable to substantially reduce the length of or completely eliminate the linear, rigid pipe or tube section that is an integral part of previously described moving valve pumps. In previously described moving valve pumps known to the inventors, such pipes provide a larger defined volume of blood for building momentum and causing forward flow with the forward stroke of the tube or pipe-valve assembly. Moreover, drive elements such as magnets can be placed on such pipes or tubes. To, for example, provide lighter weight, less vibration, a smaller pump size and better anatomical fit in the patient, several embodiments of the pumps of the present invention eliminate the tube or pipe found in other moving valve pumps and compensate for any smaller blood volume movement with increased valve action. In general, there is little space for a pipe or tube in addition to a suitable length of long-lived stretchable blood conduit in the upper right chest cavity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Other aspects of the invention and their advantages will be discerned from the following detailed description when read in connection with the accompanying drawings, in which:
[0035] FIG. 1 is a view of one embodiment of a pump of the present invention implanted in a patients upper right chest and connected to the patients ascending aorta by means of two grafts extending from the pump.
[0036] FIG. 1A is a view of the ascending aorta without coronary artery bypass grafts.
[0037] FIG. 1B is a view of one embodiment of a cylindrical, implantable structure or device having integral, crossing blood flow pathways.
[0038] FIG. 1C is a view of the aorta with the cylindrical structure of FIG. 1B inserted therein to establish a serial blood flow connection between the pump and the aorta.
[0039] FIG. 2 is a view of a human heart with two coronary artery bypass grafts connected between the ascending aorta and the coronary arteries on the surface of the heart.
[0040] FIG. 3 is a side, transparent view of the pump of FIG. 1 including an electric motor and speed reducing gear mechanism for actuating the pump.
[0041] FIG. 3A is a side view of a planetary gear arrangement that reduces the speed of the rotating motor in FIG. 3 and includes rotating planet gears that can be connected to a carriage which rotates the eccentric bearing of FIG. 3 to drive the pivot arm and oscillate the valve.
[0042] FIG. 4 is a mid-cross sectional view of the pump shown in FIG. 3 .
[0043] FIG. 5 is a perspective view of another embodiment of a pump of the present invention including a direct electric motor drive mechanism.
[0044] FIG. 6 is a mid-cross sectional view of the pump shown in FIG. 5 .
[0045] FIG. 6A is a cross-sectional view of another embodiment of a pump of the present invention including two moving valves and a direct electric motor drive mechanism.
[0046] FIG. 6B is another cross-section view of the pump of FIG. 6A .
[0047] FIG. 7 is a view of another embodiment of a pump of the present invention including a hydraulic drive mechanism.
[0048] FIG. 8 is a perspective view of an embodiment of a low regurgitant valve suitable for use in the pumps of the present invention wherein the valve ports are in an open position.
[0049] FIG. 8A is a side view of valve ports of the valve shown in FIG. 8 with the attached flexible membrane in an open state.
[0050] FIG. 8B is a side view of valve ports of the valve shown in FIG. 8 with the attached flexible membrane in a closed state.
[0051] FIG. 9 is a perspective view of the valve shown in FIG. 8 , wherein the valve ports are in the closed position.
[0052] FIG. 10 is a perspective view of another embodiment of a valve suitably shaped for use in the pump shown in FIG. 5 .
[0053] FIG. 11 is a diagram of the interrelationship between the electro-cardio-graphic signal, the patient's contracting left ventricle, the blood flow leaving the left ventricle and the moving valve action of the pump of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0054] The pumps of the present invention can, for example, assist or augment cardiac output via in-series placement with a blood vessel such as the ascending aorta just above the heart of a patient suffering from heart disease. The pumps of the present invention can, for example, alternatively or additionally be placed in series connection with the pulmonary artery. In several embodiments of the pumps of the present invention, a multi-stroke or oscillating valve is used to induce blood flow. As used herein, the term “multi-stroke” refers to a valve that oscillates (that is, moves forward and rearward) more than once for each left ventricle contraction.
[0055] Referring now to the drawings, wherein like reference numerals refer to the same item, there is shown in FIG. 1 a pump 100 connected to the ascending aorta at the output of the patients heart 10 . In a fully implanted pump configuration as illustrated in FIG. 1 , the pump 100 is be placed close to the ascending aorta in the upper right chest cavity. Because there is limited space in the right upper chest, especially in small patients, it is desirable that the size of the pumps of the present invention be small, and that the form factor of the pump be compact. In placement in the upper right chest, the pump will displace a certain volume of the upper right lung. The displaced lung volume is a relatively small penalty to pay, however, because there is relatively little gas diffusion occurring in this upper portion of the lung.
[0056] Typically, the weight density of the pump 100 and other pumps of the present invention will exceed the weight density of the lungs. This difference in weight density necessitates connecting the pump to some relatively fixed structure such as the patient's rib cage. The rib cage conveniently surrounds the space in the upper right thorax. Such fixation can, for example, include suturing the pump to one or more ribs for stabilization.
[0057] In the embodiment of FIG. 1 , pump 100 is placed in series connection with the ascending aorta via two flexible connecting conduits such as synthetic grafts 105 and 107 , which are, for example, respectively sewn to two severed ends of the ascending aorta. The blood leaving the heart flows through the lower ascending aorta 12 into the inflow graft 105 , through the pump 100 and back to the upper ascending aorta 13 by means of the outflow graft 107 . It is an important advantage that this pump connection can be made without excising or removing any portion of the aorta. The reason this is important can be seen in FIG. 2 , which illustrates vein grafts 16 that are connected from the ascending aorta to the coronary arteries of the heart. Millions of heart patients have had coronary artery bypass surgery and have such vein grafts 16 connected to their ascending aorta. If a portion of the aorta had to be removed, those grafts connected to the removed portion of the aorta would be destroyed or, at the very least, would have to be surgically reconnected. Instead, the pump 100 and its connections are preferably configured such that a continuous blood flow pathway is established without removing a section of the aorta. One way of accomplishing this objective (as illustrated in FIG. 1 ) is to effect a single cut across or trans-secting the aorta (preferably below any bypass graft connections) and, subsequently, connect the end of the pump's inflow graft 105 to the lower cut end of the ascending aorta. The end of the pumps outflow graft 107 is connected to the upper end of the trans-sected ascending aorta. The pump is thus placed in series with the heart, which avoids the problems associated with establishing a blood flow pathway that is in parallel with the heart.
[0058] Under these circumstances, the form of the pump's blood pathway minimizes pump and connection size and provides a good fit to the available anatomy. The blood flow pathway or conduit 120 (as described below) in the pump 100 is, for example, arcuate and has a radius of curvature of greater than 180°. The flow conduit 120 can have a relatively tight radius of curvature (for example, approximately 0.75 to 2 inches). A housing 130 encompasses conduit 120 and is similarly curved or arcuate in shape.
[0059] An alternative to the aortic connection discussed above is shown in FIGS. 1A, 1B , and 1 C. In this embodiment, a generally cylindrical flow structure or device 110 is dimensioned to fit inside, for example, the ascending aorta and is inserted into the aorta through a single longitudinal incision in the aorta. This connection method can be used in a section of aorta that does not have attached coronary artery grafts. Use of the cylindrical structure 110 does not require the trans-section of the aorta and can be used for temporary or permanent attachment to the aorta. Traversing the longitudinal incision in the aorta are the inflow and outflow grafts 105 and 107 , respectively, coming from the pump 100 . Within the cylindrical structure 110 are crossing blood flow pathways 112 and 114 . Blood flow passes from the proximal or lower aorta into flow pathway 112 of structure 110 and into inflow graft 105 . Blood exits the pump 100 via outflow graft 107 and flows into the distal or upper aorta through flow pathway 114 of the cylindrical structure 110 . Preferably, the axial length of flow structure or device 110 is minimized. For example, in certain embodiments, the length of flow structure or device 110 is preferably no more than 3 cm and, more preferably, no more than 2 cm.
[0060] FIG. 3 is a side view of pump 100 . In the illustrated embodiment, inflow graft 105 connects seamlessly with a moveable (for example, a stretchable and/or corrugated) blood flow conduit 120 within an opening in a header portion 132 of housing 130 . The blood flow pathway through the grafts 105 and 107 and pump 100 is completed by a similar connection of the outflow graft 107 to corrugated blood flow conduit 120 in a second opening within header 132 . The grafts 105 and 107 can, for example, be commercially available FDA-approved flexible DACRON® or TEFLON® vascular grafts. The stretchable corrugated blood flow conduit 120 is specially designed and constructed so that it can be extended and compressed along its length as a valve 140 oscillates. Valve 140 is, for example, placed inside the blood conduit 120 approximately midway in the curved length of the conduit 120 . In several embodiments, valve 140 is attached (for example, by an adhesive) around the perimeter thereof to blood flow conduit 120 . As described above, the walls of the conduit 120 can be corrugated, stretchable or otherwise moveable along the path of movement of valve 140 to allow movement (for example, via contraction and expansion) of the conduit 120 as the valve 140 moves back and forth. In the case that conduit 120 is corrugated, the corrugation of conduit 120 is preferably designed to have the shallowest valleys possible on the blood-contacting surface consistent with a total wall strain from compression and extension not exceeding 15%. The conduit wall material can, for example, be CORETHANE® polyurethane, which is an implant grade, blood compatible polyurethane.
[0061] In one embodiment, a pivot arm 150 captures valve 140 within conduit 120 . One end of the pivot arm 150 is attached to pivot point 152 and the other end of the pivot arm 150 captures the valve 140 . In the illustrated embodiment, an opening or volume 154 formed in the base of the pivot arm 150 provides space for an eccentric roller bearing 160 . The rotation of bearing 160 causes the oscillation of the pivot arm 150 at its valve end and, thereby, oscillation of valve 140 .
[0062] A gear system including, for example, one or two sets of planetary gears can be used to reduce motor rotation speed. For example, FIG. 3A illustrates an embodiment of a set of planetary gears 162 that reduces the motor's rotational speed to the rotational speed needed to rotate the eccentric bearing 160 which oscillates the pivot arm 150 . A sun gear 164 is driven by the motor rotor and, in turn, drives each of the four planet gears 162 as they travel around and are captured by the stationary ring gear 166 . A carriage 169 (see FIG. 4 ) connects to the four axels 168 of the planet gears 162 and drives the eccentric bearing 160 .
[0063] If there are two planet gear sets, they can be arranged on both sides of the motor for balance. An eccentric roller bearing connected to one or both the planet gear carriages can induce the needed oscillatory motion in one or both the pivot arms. The shape of the cut out section in the pivot arms that contact the roller bearings will determine the specifics of the oscillatory motion.
[0064] To be implantable, the motor, gears, bearings and pivot arms of the present invention are preferably resistant to the corrosive environment of the body. The motor stator and rotor can, for example, be encased in a hermetically sealed corrosion resistant titanium case. The gears can, for example, be constructed of a corrosion resistant engineering plastic such as polyetheretherketone (PEEK). The eccentric bearing can, for example, be constructed of corrosion resistant ceramic rolling elements and races.
[0065] As valve 140 moves forward, it's valve ports close and valve 140 drives blood forward toward the outflow graft 107 . The motion of valve 140 is then reversed and it's valve ports open during repositioning of valve 140 for the next forward motion. The distance traveled in any one direction can, for example, be 1 to 2 centimeters. The cross sectional area of the valve 140 can, for example, be 5 square centimeters. As one example, the valve stroke of such a valve can be 1.6 centimeters, resulting in a displaced volume of 8 milliliters. It has been found by experimentation that at cycle rates between, for example, 8 and 20 cycles per second, an aqueous fluid will flow continuously forward because of a momentum effect even though roughly half the time the valve 140 is moving backwards. For example, three cycles of 1.6 centimeter valve movement of the above-described valve displaces roughly 3 times 8 or 24 milliliters of blood and the actual flow in the forward direction could be the same or even greater than this amount. If this pumping routine occurred late in the ventricular contraction period (that is, in the later half of systole) when a failing left ventricle is too weak to eject blood by itself, an incremental output of about 24 milliliters or greater can be realized. This output would be enough extra flow to compensate for the low cardiac output found in typical heart failure.
[0066] A very space and energy efficient drive mechanism for the rotating bearing 160 is a brush-less direct current or DC motor 170 that is connected to one or more sets of planetary gears as described above. In one embodiment, motor 170 includes a stationary stator 172 and a rotor 174 positioned within a space or chamber 134 within housing 130 . A planetary gear speed reduction of 3 to 1 would, for example, translate a motor rotation speed of 3,000 revolutions per minute to three revolutions of the bearing 160 in 180 milliseconds. In this example, the motor 170 can be started prior to the desired assist period and reach a speed of 3,000 RPM, The motor 170 can be stopped after the desired number of assist cycles. Once again, to balance forces, two sets of planetary gears, eccentric bearings and pivot arms can be placed on opposite sides of the motor and the pump, each driven by the respective ends of the motor rotors axel.
[0067] FIG. 4 is a mid-cross sectional view of pump 100 . Valve 140 , is driven by pivot arm 150 as described above. The motor stator 172 induces rotation in rotor 174 , which, in turn, rotates the eccentric bearing 160 through the planetary gears 162 .
[0068] Design work and bench testing have demonstrated that it is possible to pump a sufficient volume of fluid (namely water, which for the test purposes was equivalent to blood) by oscillating single valve 140 within moveable conduit 120 without an associated pipe or tube. Elimination of such a pipe or tube is facilitated, for example, by use of a mechanical connection between the moving valve and the drive mechanism such as an extending arm (for example, pivot arm 150 ) which mechanically connects valve 140 to a drive mechanism such as motor 170 . In that regard, in a number of previously described moving valve pumps, it is necessary to place drive elements such as magnets on a linear pipe or tube in which the moving valve is placed. Valve 140 moves (oscillates) in an arcuate path as a result of its connection to pivot arm 150 . Although a single moveable valve can provide sufficient flow, more than one moveable valve can be used in the pumps of the present invention. In the case that two valves are used, the motion of the valves can be out of phase by 180 degrees so that one valve is moving forward while the other valve is moving rearward.
[0069] As described above, the actuating pivot arm 150 connects the valve 140 to a drive mechanism, which in the embodiment of FIGS. 3 through 4 is the brushless, direct current electric motor 170 that is speed reduced by a gear mechanism. Other drive mechanisms can be used to oscillate the valves of the present invention. For example, an electromagnetic motor without gears can be used to directly actuate a pivot arm. In that regard, FIG. 5 illustrates an embodiment of a pump 200 of the present invention in which a blood conduit 220 is positioned between a direct drive electric motor 270 and a pivot point 252 of a pivot arm 250 . The stretchable corrugated blood flow conduit 220 is formed in a curvilinear fashion and has a single one-way valve 240 placed generally in the mid-position of conduit 220 . The valve 240 is attached to pivot arm 250 , which is made to oscillate with an arcuate motion driving the valve 240 forwards and backwards in the blood flow pathway 220 . When driving forwards, valve 240 is closed and accelerates the blood into the patient's circulation. When driven backwards, the valve ports of valve 240 open, allowing the momentum of the blood to continue forward blood flow. This oscillating valve movement occurs for one to several or more cycles (for example, from 1 to 10 cycles of from approximately 1 to 20 millimeters, and preferably 5-20 millimeters, in length) during each natural heart beat, depending on the degree of intended assist for the failing left ventricle.
[0070] The pivot arm 250 operatively connects the valve 240 to the motor 270 , which powers the oscillating pivot arm motion. In the illustrated embodiment, motor 270 includes three curved or arcuate magnetically conductive plates 272 a , 272 b and 272 c . The magnetically conductive material of plates 272 a , 272 b and 272 c can, for example, be a high-ferrous content steel suitably coated to protect against corrosion. The plate ends are magnetically connected with end plates 273 , which can be made from the same material as the plates 272 a , 272 b and 272 c and placed to establish the magnetic circuit. Permanent magnets 274 a and 274 b made from, for example, neodymium-iron-borate are placed on the surfaces of plates 272 a and 272 c that face plate 272 b . The magnetic flux lines on each side of plate 272 b are of opposite polarity, with north to south in one gap and south to north in the other gap. Curved coil 276 wraps around plate 272 b . The electrically conductive wire of coil 276 can, for example, be made from copper or aluminum, which is preferably suitably coated to prevent corrosion. Unlike other moving valve pumps, the present inventors have found that a lighter weight of the coil 276 (as compared to a moving magnet or magnets) allows acceleration and deceleration with less force and provides more efficient operation. In this regard, using aluminum wire provides a better mass to conductivity ratio than copper. In that regard, aluminum has approximately one-third the mass and two-thirds the conductivity of copper. Thus, for purposes of minimizing the acceleration and deceleration forces, aluminum is the preferred conductive material. An additional benefit accrues from a leverage advantage wherein the coil 276 moves at approximately twice the speed and half the force as that seen by the valve 240 . Passing electric current through coil 276 in one direction causes the coil 276 , pivot arm 250 and valve 240 to move in a first angular direction, while passing electric current through the coil 276 in the reverse direction causes the coil 276 , pivot arm 250 and valve 240 to move in the opposite angular direction. The size of electric motor 270 is determined by its Km ratio and is more related to motor force than to motor speed.
[0071] Regardless of the type of the drive mechanism employed, the position of the valve may be determined at any point in time by, for example, placing a position sensor in operative connection with the pivot arm 250 . As illustrated in FIG. 5 , a position sensor 280 can, for example, include a curved variable differential transformer, which produces a voltage proportional to the position of the pivot arm 250 and valve 240 . The transformer 280 can be curved in shape to accommodate the curved motion of the pivot arm 250 and the connected valve 240 . The derivative of this position signal with respect to time is the velocity and the second derivative is the acceleration. Using this information, a microprocessor and motor controller (not shown in FIG. 5 ) can induce virtually any desired motion profile.
[0072] In the embodiment of a gearless electromagnetic motor drive discussed above, the valve 240 is placed at an intermediate position on the pivot arm 250 , between the pivot point 252 and the moving coil 276 of the motor 270 . As clear to one skilled in the art, however, in the case of an electromagnetic motor, either the magnet or the coil can be move and the opposite element held stationary. As with motor 170 , any corrodible elements of the motor 270 are preferably appropriately fabricated or coated to prevent corrosion.
[0073] In general, it is easier to manufacture a small pump using a gear-speed-reduced motor drive mechanism as described in connection with FIGS. 3 through 4 than using a gearless electromagnetic motor as described in connection with FIGS. 5 and 6 . In the case of a gearless electromagnetic drive mechanism as described in connection with FIGS. 5 and 6 , however, compactness can be accomplished by forming the cross sectional area of the electric coils 276 , the blood flow conduit 220 and the valve 240 in the form of a racetrack (that is, in the form of an oval or a rectangle with rounded corners). Such a racetrack form is wider than it is high, making the pump 200 somewhat wider but have less stacked height. The height of the pump is the dimension most likely to interfere with the limited dimensions of the chest cavity.
[0074] Motion of the valve 240 induced by the ejection of the blood from the left ventricle can also be sensed via, for example, sensor 280 (as described above) in operative connection with pivot arm 250 and, thereby, with valve 240 . Sensor 280 is placed in communicative connection with the microprocessor/controller. The sensed valve motion can, for example, be used to detect ventricular contraction, which is the time during which the left ventricle is attempting to eject blood. Once again, the preferred time for valve oscillation assist is later in the contraction period or systole when the ventricle is contracting but doing little flow work. At this time the valve 240 can more easily move blood from the ventricle because the pressure in the ventricle is high and the valve 240 simply needs to add a little more pressure to move the blood. Preferably, valve 240 is oscillated only in the later half of systole.
[0075] FIG. 6 illustrates a mid-cross sectional view of the direct electric motor drive pump 200 . The coil 276 wraps around the intermediate steel plate 272 b . Plates 272 a and 272 c , in connection with attached magnets 274 a and 274 b , create the magnetic flux that drives the coil 276 in one or the other direction depending on the direction of current in the coil. Once again, to establish a compact form factor, the electric coils 276 , the blood flow conduit 220 and the valve 240 are in the form of a race tract.
[0076] FIGS. 6A and 6B illustrate another embodiment of a pump 300 including two moveable valves 340 a and 340 b positioned within a generally linear flexible conduit 320 having an inlet 322 and an outlet 324 which can be placed in fluid connection with a blood vessel as described above. The pump 300 includes an electromagnetic motor 370 including moving coils 376 a and 376 b , an annular magnet 374 , and a ferromagnetic stator 372 . Coils 376 a and 376 b move up and down (in the orientation of FIGS. 6A and 6B ) depending upon the polarity of the voltage applied to the coils 376 a and 376 b and the moving coils 376 a and 376 b are connected to the valves 340 a and 340 b by extending or connection members 350 a and 350 b , respectively. As illustrated in FIG. 6A , the magnet 374 is interrupted to make space for a position sensor such as a linear variable differential transformer 380 , or LVDT, which provides coil position information for the valve actuator position to a control system 390 (shown schematically in FIG. 6A ) of pump 300 .
[0077] The two valve actuators of pump 300 are provided in series whereby the pump's control system forces the respective motions of the coils 376 a and 376 b to be equal and opposite, resulting in the motion of valve 340 a being 180° out of phase with the motion of valve 340 b . Such out of phase motion can, for example, operate to reduce any vibratory effects that can occur with a single valve actuator. Patient perception of pump operation can thereby be eliminated or substantially reduced. Moreover, pump 300 can operate as a positive displacement pump because one or the other valves 340 a and 340 b is always virtually closed moving forward when the pump 300 is operating. Position sensor 380 can be used in effecting such control.
[0078] Another drive mechanism that can be used in connection with the pumps of the present invention is based on pressurized hydraulic fluid. For example, an electric motor may drive an internal gear or gerotor hydraulic pump producing fluid at a pressure approximately ten times that of aortic blood pressure. This relatively high pressure enables driving of an actuator such as a vane, which is in operative connection with a pressurizing or moving valve, to be accomplished with only a few milliliters of fluid. The fluid can, for example, be switched to one or the other side of a vane, piston or piston equivalent. The switching produces an oscillatory movement of the piston, which in turn is connected to the actuating pivot arm moving valve combination.
[0079] FIG. 7 illustrates a representative embodiment of a pump 400 of the present invention in which a hydraulic pump 470 develops pressurized fluid at a high-pressure output port. Fluid is returned to hydraulic pump 470 via a low-pressure return port. The fluid lines from the hydraulic pump 470 are connected to manifold 472 , which is attached to a four-way, two-position spool valve 474 . The valve 474 is electrically activated to one of two positions. In the first position, the spool valve 474 introduces high-pressure fluid into a fluid chamber 434 at port 436 . A vane 476 moves in response to the high-pressure fluid and moves the pivot arm 450 and its connected pressurizing valve 440 within the blood conduit 420 . With spool valve 474 in the second position, high-pressure fluid is introduced into chamber 434 on the opposite side of vane 476 causing vane 476 to move within a chamber defined by walls 476 ′ and 476 ″, thereby effecting repositioning of the pivot arm 450 and the attached valve 440 . In the case of a hydraulic drive mechanism, the hydraulic pumping source can be separate from the blood pump, thereby allowing the blood pump to fit more easily in the upper right chest of the patient.
[0080] For each of the drive mechanisms described above, the blood-moving or pressurizing valve preferably requires little reverse blood flow to close the valve. Excessive back flow during valve closure steals from the volumetric efficiency of the pump. Unless valve 140 and other pressuring valves of the present invention are volumetrically efficient in their opening and closing actions, substantial inefficient valve closing backflow will occur as the valve opens and closes several times within a single ventricular contraction time period. As illustrated, for example, in FIGS. 8 through 9 , valve 140 can include a plurality of ports 142 formed in a frame 146 . Each port 142 has a closing mechanism or valve such as a leaflet or a membrane 144 in operative connection therewith. The leaflets or membranes 144 collectively open and close the valve 140 . Using a plurality of relatively small valve ports 142 minimizes the relative amount of reverse blood flow needed to close the valve 140 .
[0081] For valve longevity purposes it is desirable to minimize the strain experienced by the valve leaflets 144 . The valve leaflets or membranes 144 can, for example, be made from polyurethane with a thickness of approximately 10 mils. Strain minimization can, for example, be accomplished by having the leaflets or membranes 144 (as shown in FIGS. 8 through 9 ) hinge without complex curvature or wrinkling. In general, complex curvature refers to a change in the direction of curvature over the surface of the leaflet or membrane as, for example, occurs in a crinkle which curves in more than two dimension as opposed to a simple curve which occurs in two dimensions. Overstressing of membranes 144 can lead to material fatigue and valve membrane fracture. In the embodiment of FIGS. 8 through 9 , each of the plurality of membranes 144 is attached to valve frame 146 along a generally linear path to create a linear hinge 144 a . As the valve 140 is retracting, the membranes 144 open up to pass blood though the valve 140 . When the valve 140 reverses to move forward, the membranes 144 close with very little backward blood flow. As illustrated, for example, in FIGS. 8 through 9 , the valve frame 146 , valve ports 142 and membranes 144 are preferably angled tilted at an angle θ (see FIG. 8B ) of, for example, an angle of 30 to 45 degrees with respect to a radially oriented plane bisecting conduit 120 (or with respect to the general direction of blood flow through conduit 120 as represented by the arrow in FIG. 8B ) to minimize blood-closing volume. With the support of the valve membrane frame 146 or seating structure, the membranes 144 push the blood in a forward direction upon forward motion of valve 140 .
[0082] FIGS. 8A and 8B show a side view of a valve port 142 with the flexible membrane 144 attached at the bottom edge of the port 142 . As the valve port 142 opens, membrane 144 gradually curves upward (see FIG. 8A ) to allow blood to flow through the port. It has been demonstrated in bench testing that the membranes 144 gradually distribute bending over much of the membranes length to minimize strain.
[0083] As illustrated in FIG. 10 valve 240 , having a racetrack shape for use with pump 200 , also includes a plurality of ports 242 formed in a frame 246 . Likewise, each of valve ports 244 has a flexible leaflet or membrane 246 in operative connection therewith via a generally linear hinging attachment 246 a.
[0084] The valves of the present invention provide for substantially failsafe operation of the pumps of the present invention. In that regard, if power to the pump fails or the pump otherwise malfunctions, the patient is no worse off than if the pump were not in place. As the valve ports require only a few millimeters of mercury or less increased pressure to pump blood through the valve ports, blood is free to flow through the flow conduits of the pumps of the present invention even if the pump is inoperable.
[0085] When the pumps of the present invention are connected in series with the ascending aorta, a small amount of leakage through the blood-moving valve can be provided to allow reverse blood flow during the heart's resting period or diastole. This reverse flow will supply blood to the coronary arteries and the heart itself. This leakage can be produced by purposeful misalignment of one or more of the leaflets and sealing structure/frame (to effect incomplete closure of the corresponding valve openings) or by having a permanent hole in the valve structure. Approximately 500 milliliters per minute of blood leakage is required for coronary flow.
[0086] As described above, the corrugated blood conduit 120 and the valve leaflets or membranes 144 can be constructed of polyurethane having a wall thickness of approximately 10 mils. Bench testing has demonstrated flexing life well in excess of 200 million cycles as long as the induced combined strains in the polyurethane do not exceed 15%.
[0087] As also described above, if the corrugation valleys in conduit 120 are too deep, there is a risk of blood stagnation and clotting in the valleys of the corrugation 120 . The optimum corrugation design keeps the strain below 15% and minimizes the depth of the corrugation valleys. This optimization can be facilitated by having the pressure outside the conduit 120 approximately equal to the pressure inside the conduit 120 and thereby eliminating pressure induced strain in the conduit 120 . If the enclosure formed by housing 130 and header 132 of the assist device or pump 100 seals in a fluid tight fashion and encloses a certain volume of fluid 138 (see FIG. 3 ) as readily determined by one skilled in the art for a particular pump geometry, the pressure on both sides of the conduit wall will be automatically equalized. Additionally or alternatively, generally rigid elements 122 (see FIG. 3 ) can be placed around the circumference of conduit 120 at various positions thereon to assist in maintaining the shape thereof. One or more of such elements can be attached to and supported by housing 130 .
[0088] Depending on the particular drive method used, the control system for the pump can vary. A control system for use in connection with blood pumps is described, for example, in U.S. Pat. No. 6,375,607 by Prem, the disclosure of which is incorporated herein by reference. In FIG. 1 , a control system 180 in operative connection with motor 170 of pump 100 is represented schematically. As illustrated in FIG. 1 , the control system 180 can, for example, be implanted subcutaneously at a position remote from pump 100 in the upper chest of the patient and placed in communicative connection with pump 100 (for example, via wiring). The control system for valve movement of the pumps of the present invention can, for example, include a microprocessor based position servo control system. A command position signal can, for example, be compared with the actual position signal and an error signal can be generated to cause the motor to speed up or slow down depending on the sign of the error signal. The velocity, acceleration and jerk of the valve movement can all be derived from the position signal changes over time. With the motor turned off, a measure of the blood flow rate through the valve can be obtained by measuring the valve movement as blood is sweeping through the valve. Alternatively, if the valve is held in a fixed position or allowed to move slowly by the servo system, the electrical current required to resist valve movement from the blood flow can be used as a surrogate signal for blood flow rate coming from the left ventricle. The higher the blood flow rate, the more current it takes to hold a fixed valve position or to move the valve against the blood flow. This information can be used to determine the timing of ventricular systole and the timing for valve oscillation. Alternatively, an electrocardiogram can be used to time the valve oscillations. In FIG. 1 , leads 182 a and 182 b provide a signal of the heart's rhythm to control system 180 . As described above, the most advantageous time to oscillate the valve is later in systole when the heart is pumping little blood but is generating pressure that the valve can use in its forward stroke.
[0089] FIG. 11 illustrates the temporal relationship between several system variables during pump assist. In FIG. 11 , the moving valve position, the aortic root blood flow, the contracting left ventricle ( 18 a and 18 b ), and the electro-cardio-graphic signal are all juxtaposed along a horizontal time line. One ventricular contraction 18 b , is shown without pump assist. A second ventricular contraction 18 a , is shown with pump assist. In connection with the FIG. 11 , for a representative example of a normal sized male with a heart rate of 80 beats per minute, the volume of blood ejected from the failing left ventricle increases from approximately 37 milliliters to a normal level of 52 milliliters with the assist action of three cycles of the moving valve pump. Left ventricular contraction wall motion increases with assist (illustrated by the arrows drawn in connection with the left ventricle ( 18 a and 18 b ) in FIG. 11 ) as more blood leaves the ventricle with the decreased after-load resulting from the pumping action of the moving valve.
[0090] Although the present invention has been described in detail in connection with the above embodiments and/or examples, it should be understood that such detail is illustrative and not restrictive, and that those skilled in the art can make variations without departing from the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A pump includes a flexible conduit, at least one valve attached to the flexible conduit about the perimeter of the valve; and a drive mechanism to move the valve to pump blood within the conduit. The drive mechanism can, for example, be adapted to complete a single stroke during each heart ventricle contraction and/or to complete multiple strokes (that is, oscillate) during a single contraction. Another implantable pump for assisting blood flow, includes: a flexible conduit formed in an arc; at least one movable valve in operative connection with the conduit; and a drive mechanism to move the valve in an arced path to pump blood within the conduit. Another pump includes a conduit and at least one moveable valve within the conduit. The moveable valve includes a plurality of openings. Each of the plurality of openings has a closure mechanism in operative connection therewith. Each closure mechanism is operable to at least partially close the opening to which it is operatively connected when the moveable valve is moved forward and to open the opening to which it is operatively connected when the valve is move rearward. The pump further includes a drive mechanism to move the valve to pump blood within the conduit. In one embodiment, each closure mechanism includes a flap of resilient material.
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This is a continuation of application Ser. No. 829,350, filed Aug. 31, 1977, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates generally to a self-propelled underwater trenching apparatus. More particularly the present invention is concerned with the self-propelled underwater buoyant apparatus for burying pipelines or cables and the like to lay on the floor of a body of water. Uniquely, the present invention further relates to apparatus for burying pipelines or cables which may have an uneven surface that may present an obstruction to the continuous movement of the apparatus along the pipeline and cable.
DESCRIPTION OF PRIOR ART
In U.S. Pat. Nos. 3,926,003, 3,877,237, divisions of co-pending application Ser. No. 175,448 filed Aug. 27, 1971, in the name of the present inventor, there is disclosed an apparatus for burying pipelines, cables and the like in the bottom formation of a body of water. The apparatus therein disclosed utilizes high pressure fluid in the form of water jets positioned in advance of the movement of the apparatus along the pipeline to cut away a trench in the bottom formation into which the pipeline will rest. This prior art apparatus was designed to be supported by the pipeline to be buried and propelled along the pipeline by a propulsion system utilizing resiliently urged drive rollers. The drive rollers were held on a frame structure positioned on each side of the pipeline. In order to reduce the weight of the trenching apparatus on the pipeline, buoyancy tanks were provided to provide a buoyant effect that was an aid in minimizing the possible damage to any coating on the pipeline due to the weight of the apparatus and the rotating of the drive rollers. The formation was cut by a plurality of water jets positioned in the fore portion of the apparatus on each side of the pipeline and spraying cutting water jets in selected directions. Eductors were positioned aft of the jet means to suck up the cuttings and other debris that have formed in the trench by the jets. Other eductor tubes are disclosed in U.S. Pat. No. 3,368,358.
This prior apparatus was designed to be supported above and below the pipeline by means of elongated idler rollers which held the apparatus to the pipeline and were adjustable for various diameters of pipeline. This apparatus, although successful commercially in the past, is no longer in use because it possessed inherent limitations in its operation and more importantly required diver supervision to overcome various pipeline conditions.
The requirement of the presence of a diver is not only a substantial additional expense to the overall operation but slows dramatically the progress of burying of the pipeline during the work being performed by the diver to free the apparatus from any obstruction on the pipeline. Typical of these obstructions on the pipeline are the various cathodic protection devices secured to the pipeline surface to prevent corrosion of the pipeline.
Prior art trenching apparatus would not effectively and efficiently pass over such obstructions in the surface of the pipeline either because the drive rollers were unable to override the obstruction or that guiding rollers spaced in accordance with the pipeline diameter would be unable to override the cathodic protectors and still be effective to guide the apparatus along the pipeline. In instances of such obstruction, the diver must release one or more of the rollers or shift the position of the apparatus and then guide the apparatus along the pipeline until the obstruction is passed.
The requirement of diver participation in every instance when the apparatus would meet a cathodic device or other obstruction in the pipeline surface is clearly an undesirable characteristic; however, there are other drawbacks to trenching apparatus that are unable to override such obstructions. It has been found, for instance, that prior art trenching apparatus when contacting the pipeline obstruction without being capable of passing over the obstruction, permit the propulsion system to continue to urge the drive rollers in an effort to move the apparatus forwardly. Continued failure to produce such forward movement by the rotating drive rollers consequently wears away the usual corrosion resisting coating on the pipeline to expose the pipeline to the prospect of undue corrosion and the ultimate possibility of failure.
This possibility of damaging the pipeline requires constant attention by the crew manning the on-surface barge which directs the movement of the trenching apparatus. Any failure to maintain such attention produces not only undue delays in the progress of burying the pipeline but also, and more importantly, the possibility of serious damage to the pipeline.
OBJECTS OF THE INVENTION
It is the principal object of the present invention to provide a self-propelled underwater trenching apparatus for burying pipelines, cables, and the like, which minimizes the requirement of the presence of the underwater supervision of the diver to enable effective and efficient operation of the trenching apparatus to be substantially completely controlled on the water surface.
It is also an object of the present invention to provide underwater self-propelled trenching apparatus capable of overriding obstructions in the pipeline surface without requiring the presence of a diver or without causing damage to the pipeline and its coating.
This invention also has as an object the provision of underwater self-propelled trenching apparatus that selectively and alternately engages and disengages drive rollers to enable the trenching apparatus to override an obstruction in the pipeline surface.
Another object of the present invention is to provide a self-propelled underwater trenching apparatus in which the fore and aft portions of the apparatus open and close selectively and alternately to engage and disengage the drive rollers from driving engagement with the pipeline in the event that an obstruction in the pipeline surface is encountered.
Another object of the present invention is to provide a self-propelled underwater trenching apparatus for burying pipelines in which the frame of the apparatus may be temporarily bent into a more open position in order to permit drive rollers on the apparatus to override any obstruction in the pipeline surface.
A further object of the present invention is to provide for the opening and lateral extension of the frame in order to accommodate various sizes of pipeline.
A further object of the present invention is to provide a self-propelled underwater trenching apparatus capable of detecting power flow changes to drive rollers in driving engagement with the pipeline and proportioning the power flow to maintain the motivation of selected rollers having a greater resistance to moving the apparatus along the pipeline in order to override obstructions in the pipeline surface.
Yet another object of the present invention is the provision of methods for underwater trenching for the burying of pipeline in which the variations in power flow to drive rollers is detected and controlled to alternately and selectively direct power to drive rollers that are selectively and alternately in drive engagement with the pipeline.
Still another object of the present invention is the provision of a method for underwater trenching by selectively and alternately engaging and disengaging drive rollers to permit an override of an obstruction in the pipeline surface.
These and other objects of the present invention shall become more apparent upon careful study of the following detailed description and the appended claims including the following drawings:
THE DRAWINGS
FIG. 1 is a front elevational view in section and partly broken away illustrating the positioning of the underwater trenching apparatus along the pipeline and the positioning of the cutting jet means.
FIG. 2 is a side elevational view partly broken away illustrating the positioning of the buoyancy tanks, drive rollers, the cutting jets for forming the trench in the bottom formation and the airlift means for removing the formation cuttings.
FIG. 3 is a cross-sectional view taken along lines 3--3 of FIG. 2.
FIG. 4 is a cross-sectional view partly broken away taken along lines 4--4 of FIG. 2 to illustrate particularly the telescopic means, the abutment means, and the means for pivoting frame members.
FIG. 5 is a schematic illustration of the power fluid flow to the drive wheels.
SUMMARY OF THE INVENTION
The self-propelled underwater trenching apparatus and method of this invention burys pipelines, cables and the like with formation cutting water jets. The frame of the apparatus includes frame members positioned about the pipeline fore and aft. Drive rollers are connected to each frame member for selective drive engagement with the pipeline. The fore and aft portions of the frame members are movable by rams about a pivot to selectively engage into or disengage rollers out of drive engagement with the pipeline. The apparatus also may include telescopic extensible means to move the horizontal axis laterally or transversely of the pipeline. An obstruction on the surface of the pipeline is overridden by power rams between the fore portion of the frame members that separate the frame members, and may bend the frame members, to bring the forward drive rollers out of drive engagement with the pipeline. The hydraulic propulsion system motivating the driver rollers selectively directs fluid flow to the aft driver rollers in driving engagement with the pipeline to move the apparatus forwardly until the forward drive rollers have overridden the obstruction and then the ram returns the frame to its original position and the forward drive rollers again into drive engagement with the pipeline. The sequence is then reversed to utilize the forward drive rollers to move the apparatus along the pipeline until the aft drive rollers have overridden the pipeline.
DESCRIPTION OF THE INVENTION
General Description
FIGS. 1 through 4 of the drawing disclose generally the buoyant underwater self-propelled trenching apparatus 10 constituting the present invention. The apparatus is guided along pipeline P to be buried in the trench T formed by the trenching apparatus in the bottom B of a body of water W. The apparatus proceeds in the direction of the arrow shown in FIG. 2 while burying the pipeline. As the trench is dug out of the bottom formation the pipeline falls into the trench and is back-filled by the cutting debris and water currents to bury the pipeline. A barge or ship (not shown) is on the surface above the trenching apparatus to supply power and fluids required by the apparatus and to provide various other control and recording procedures.
The buoyant underwater self-propelled trenching apparatus of the present invention is composed of several elements. The buoyancy of the apparatus is controlled by the buoyancy tanks 12 and 14 positioned on each side of the apparatus 10. A frame 16 generally depicts a portion of the apparatus astride or surrounding the pipeline P. Supported on the frame are a plurality of the formation cutting jet means 18 positioned to achieve the most efficient and effective cutting of the formation. Airlift means 20 are secured to the frame and draw up the cuttings from the jets 18 and discharge them away from the apparatus. Drive roller means 22 is secured to the frame and is in driving engagement with the pipeline for propelling the apparatus forwardly along the pipeline. The drive rollers are best shown in FIG. 2.
The Frame Structure
The trenching apparatus 10 is composed basically of a frame 16 composed of frame members 24 positioned on each side of the pipeline. The structural rigidity of the frame is enhanced by connection with manifold 26 which is supplied with air pressure by suitable pipes 28 connected to the manifold by connections 30. The pipes 28 are connected to the surface vessel from which they receive the supply. The manifold 26 may be any suitable size and shape but it is preferred to be in the form of an elongated steel cylinder closed at the ends.
Positioned on each side of the pipeline are the frame members 24 formed from elongated tubular upright beam members 32 extending vertically upwardly at the forward and aft ends of the apparatus. Connected between these upright beam members 32 are upper and lower bars 34 and 36 suitably connected to the upright beam members 32 to form support for the drive roller means 22. At the upper end of each beam member 32 is a bearing 38. Journaled within the bearing 38 to permit pivotal movement of the frame members 24, are tubular pivot shafts 40 extending the length of the apparatus on each side of the pipeline. The frame members 24 including the upper and lower bars 34 and 36 to which the drive roller means 22 are attached are able to pivot about each pivot shaft 40.
Connected between the vertical beam members for pivotal movement of the frame members 24 are double acting rams 42 and 44 having a pinned rod and yoke connection to the upright beam members 32 as shown at 46. This connection 46 permits some angular movement between the beam members 32 and the end of the rod in the connection 46. Ram 42 is positioned in the forward end of the apparatus and transversely contacts the fore portion of each of the frame members 24 while ram 44 is positioned at the aft end of the apparatus and operates independently on the aft portions of each frame member 24.
The rams 42 and 44 may be suitably powered in any manner but preferably are operated hydraulically through suitable hydraulic hose connections 48 extending from each end of rams 42 and 44 and connected to ram actuator 50 which operates to actuate selectively ram 42 or 44 to open or close the frame members 24. Suitable control mechanism extending to the surface enables the crew on the barge to open or to close independently foreward ram 42 or aft ram 44.
To limit the movement of the frame members inwardly upon a closing force being applied by either forward ram 42 or aft ram 44 are extensible abutments 52 and 54 extending between the upright beam members 32 in the fore portion of the frame and also positioned to extend between the aft portion of the rear member. The abutments are held stationary by being connected to web 56 that may be welded to the underside of the manifold 26. The abutments 52 and 54 are easily extensible by reason of the screw threads, as shown, to permit the trenching apparatus to accommodate large pipeline diameters. These abutments may contract into their respective housings 58 and 60 which are connected to the web 56. When abutments are extended to a pre-selected distance to accommodate a pipeline of known pipe diameter, the abutments strike the inside surfaces of the upright beam members 32 at 62 to limit any further inward movement of the upright member 32 and therefore frame member 24 should there be further action of the fore or aft rams 42 and 44.
In addition to the pivotal movement of the frame member 24, frame members are laterally extensible by telescopic means 64 extending on each side of the pipeline to contact the pivot shaft in both the fore and aft portions of the apparatus, as best shown in FIG. 4. Each telescopic extensible means 64 is secured at one end 65 to the side of the manifold 26 and includes a threaded rod 66 received into elongated sleeve 68 extending on both sides of the pivot shaft 40. Threaded nuts 70 and 72 on each side of each sleeve 68 hold the telescopic extensible threaded rod 66 in any pre-selected position limited only by the diameter of the pipeline and the length of threaded rod 66. Companion telescopic extensible support rods 74 as shown in FIG. 3, may be positioned longitudinally between the threaded telescopic extensible threaded rods 66 and are secured in the same manner to the manifold as by welding at 65. The rods 74 are passed through the pivot shaft 40 and are slidable in non-threaded sleeves 76 extending from the pivot shaft to support the sliding movement of rod 74 on each side of and through the pivot shaft 40.
It should be apparent that by coordinated operation of nuts 70 and 72 and the absence of pressure applied to rams 42 and 44, that the frame members 24 and the pivot shafts 40, which provide the horizontal axis for the pivoting of the frame members 24, may be moved transversely or laterally toward or away from the pipeline P. The adjustments and extensions of the frame are useful to accommodate various diameters of pipeline.
Rollers and Propulsion
The roller means 22 include pairs of forwardly positioned rollers 78 and 80 and aft rollers 82 and 84. One roller of each pair is positioned in the opposing frame member 24, as is best shown in FIGS. 2, 3 and 4. The rollers each have axes 86 extending above and below the upper and lower surfaces respectively of the roller and are journaled for rotation in bearings 88 which are bolted to upper and lower bars 34 and 36 by securing means 90 such as the nut and bolt arrangement shown. The roller means 22 are secured between the upper and lower bars 34 and 36 for rotation within the journal 88 and have no other movement independent of the frame member 24.
Each roller in the roller means is rotated by a fluid actuated motor 92 of conventional design. As best shown in the schematic drawing of FIG. 5, the fluid motors 92, 92, 92, 92 operate drive rollers 78, 80, 82 and 84 in a unique manner to assure the movement of the pipeline. The hydraulic or other fluid from a source on the barge is admitted to hose 94 under pressure and directed into primary flow divider 96. Secondary flow dividers 98 and 100 direct the fluid for the forward and aft drive rollers respectively through appropriate hoses 102 and 104 and 106 and 108. Each of these hoses directs fluid into the power side of the motors connected to their drive rollers to rotate the drive rollers through conventional gear boxes 110. Return fluid is extracted by hoses 112, 114, 116 and 118 through suitable valve arrangements 120 and out collector hoses 122 and 124 through valve 126 to return hose 128. Collector hoses may be half inch diameter while feed hoses 102 through 108 may be quarter inch diameter. Supply hose 94 and return hose 128 may then be three-quarter inch diameter. The sizes of the hoses are optional and may vary substantially in accordance with the apparatus design.
The flow dividers operate to direct greater or lesser fluid flow into the respective feed hoses in accordance with the feed hose back pressure sensed by the flow dividers. In the event of greater back pressure being sensed, for instance, in feed hose 102 and 106 for forward rollers 78 and 80, sufficient fluid flow is delivered through flow dividers 96 and 98 into these same feed hoses 102 and 106 to meet the greater power needs of these rollers and maintain the speed of rotation of the rollers. Similarly should aft drive rollers 84 and 82 be slipping and rotating freely or should they be disengaged from driving contact with the pipeline, such as when an obstruction in the pipeline is to be overridden, a drop in pressure will be experienced in feed hoses 104 and 108 that would be sensed in the flow divider 96. Fluid pressure automatically is then reduced in the direction of these drive rollers 82 and 84 having ineffective drive engagement with the pipeline. At the same time sufficient fluid flow would be directed to drive rollers 78 and 80 assuming they maintain driving engagement with the pipeline. Such driving engagement would be sensed by the flow dividers 98 and 96 from the back pressure in hoses 102 and 106.
It should be clear that should either of the forward position drive rollers 78 and 80 or the aft positioned drive rollers 82 and 80 begin to slip or be in disengaged or otherwise experience inoperative driving engagement, flow divider 98, for the forwardly positioned drive rollers 78 and 80, and flow divider 100, for the aft position drive rollers 82 and 84, would accordingly direct sufficient fluid pressure to that drive roller exhibiting the greatest back pressure and maintain the most effective drive roller engagement to move the apparatus.
Alternatively, each motor 92 may be powered by a positive displacement pump which constantly directs the same amount of fluid to each motor irrespective of one or more motors experiencing more or less resistance to rotation. Thus should the selected motors be disengaged they would rotate at the same speed as engaged motors. The purpose of this modification construction is to be able to select the speed of rotation for the drive rollers and thus control the speed of the apparatus down the pipeline.
The forward drive rollers 78, 80 are preferably positioned between the formation jet cutting means 18 as best shown in FIG. 2 and more particularly, aft of the forward jet cutting means. The positioning of the drive roller in such a manner enables the drive roller to follow the pipeline unimpeded along the clear shallow trench formed by the forward jet cutting means and guide the apparatus along any pipeline curvature. Aft positioned jets cut the formation deeply to form the trench precisely along the path of the pipeline.
In addition to the drive roller means 22, a top roller 130 is secured to the apparatus and depends from the manifold 26. This top roller 130 is journaled along a horizontal axis at 132 into a yoke 134 secured to a vertical shaft 136, as best shown in FIGS. 1 and 4. The shaft 136 is adjustable vertically by telescopic threaded rod 138. This rod is received into the upper end of the hollow shaft 136 producing sliding movement of the shaft 136 by operation of nut 140 to screw the shaft vertically within the housing 142. The shaped design of top roller 130 enables it to act as an idler roller to rest on top of the pipeline P and to center the pipeline to achieve the most effective drive engagement with the drive rollers 78, 80, 82 and 84.
A bottom roller 144 extends along the horizontal axis and is also an idler roller freely rotating on shaft 146 when in contact with the bottom of the pipeline and the underwater trenching apparatus is moving along the pipeline. The bottom roller is designed to prevent the apparatus from being dislodged from the pipeline by upward movement of the apparatus. However, with sufficient upward movement that might otherwise damage the apparatus if it were rigidly held in position on the pipeline, a breakaway fastening means 147 is provided in the form of a shear pin 148 holding the yoke 150 to the plate 152 secured to the frame member 24. Pivot shaft 154 passes through the yoke 150 and plate 152. The shear pin 148 holds the bifurcated yoke 150 to the plate 152 to hold the bottom roller 144 in horizontal position. Should the apparatus then be forced upwardly with sufficient force, the shear pin 148 will fail and bottom roller 144 will swing downwardly about pivot 154 thus releasing the trenching apparatus from the pipeline.
The present apparatus also is provided with an additional roller in the form of counter roller 156 as best shown in FIG. 2. This counter roller rests at all times on the top of the pipeline to record the footage of the pipeline being buried. Suitable signals and recording devices are transmitted to the surface barge to enable the crew to determine the progress of the apparatus burying the pipeline and also to detect instantaneously any stoppage of the burying.
Cutting Jet Means and Air Lifts
The cutting jets 18 are preferably positioned in pairs similarly situated along the opposed frame members 24. As best shown in FIG. 2 the cutting jets are positioned to extend in stepwise fashion more deeply into the trench and, other than the forward jets, are angled inwardly toward the aft end of the apparatus. The forward jets are higher, vertical and spaced apart a greater distance. The cutting jets in the leading position in the fore part of the apparatus are shown at 160 and are formed from high pressure tubing into a cutting head 162. This cutting head is provided with a multi-holed bolting frame or fishback 164 secured by suitable bolts 166 to complementary frame fishback 168 welded to upright 32. If desirable, additional cutting heads could be added to the apparatus and be within the scope of the invention. Each cutting head is provided with a plurality of jet nozzles 170. Each of these jet nozzles is selected to be directed at an angle and may range from 5° to 270° relative to the vertical axis of the cutting head. Horizontal disposition of the angle of the jet nozzle varies usually within a full half circle or greater.
The nozzles 170 secured to the high-pressure tubing 162 are preferably protected by a plurality of U-shaped guards 172 which protect the nozzles from contact with the formation or dislodged debris. The guards are formed from single rods bent into a U-shaped form and welded to the tubing. Preferably, and as shown in FIG. 1, the nozzles are positioned on the tubing 162 in a plurality of vertical rows, preferably three. In the manner described in my previous patents, the rearward thrust of these jet nozzles may be offset by tilting, turning, or reversing the position of the jet nozzle.
The forward cutting jets being positioned higher and being spaced wider apart are effective to form an initially wide but shallow trench which clears a path for the forward drive rollers to guide the apparatus to move along the pipeline and shift the apparatus should a pipeline curvature be encountered. The following cutting heads positioned aft of the forward cutting head and aft of the forward drive rollers 78, 80 are effective to produce a trench of the desired depth. These cutting heads will have been guided and shifted by the forward drive rollers 78, 80 to cut the formation directly beneath the pipeline.
Cutting heads 174 are each secured in a fashion similar to that described for the cutting head 160 except that the corresponding tubing is rigidly secured to the upper and lower bars 34 and 36 as best shown in FIGS. 2 and 3. The only significant difference is that the fishback, being secured to the upper and lower bars 34 and 36, is essentially L-shaped as shown in 176 in FIG. 3. As can best be seen from FIG. 2, cutting head 174 extends slightly below cutting head 160 and behind drive rollers 78, 80 so that all the jet nozzles on cutting head 174 are exposed and effective to cut the formation. Similarly, cutting head 178 and 180, again each being secured to the frame member 24, extend further downwardly into the trench in the manner describing the relationship between cutting head 174 and 160. As best shown in FIG. 1, the high-pressure tubing 162 is angled at 182 in order to have the cutting heads directed downwardly and inwardly at a angle up to 30° from the vertical. Each of the cutting tubes is secured at 184 to individual water hoses 186 which extend to the surface barge where suitable pump apparatus applies high pressure water to be discharged through individual nozzles.
The airlift means 20 is secured to each frame member 28 in a manner similar to that described for the cutting tubes. The tubing used for the airlift means positioned in the aft end may be of larger diameter as shown at 188. Secured to the upper end of airlift tubing 188 by coupling 190 is large diameter flexible hose 192 which extends well above the apparatus and is free to discharge the cuttings and debris. To operate the airlift means, high pressure air is supplied through nozzle at 198. Air rising in the tubing 188 causes a suction to lift the cuttings. The air is supplied to the air nozzle 194 through air pipe 196 to which is secured a flexible hose 198 connected to air supply in the manifold 26. Preferably the lower end of the airlift tubing 188 is angled inwardly to approximate the inward angle of the cutting tubes as best shown in FIGS. 1 and 4.
Forwardly positioned airlift 200 may be the same size as the airlift tubing 188 or smaller and is secured to the upper and lower bars 34 and 36 in the same manner as the aft airlift tubing. Discharge by the airlift means 200 is through discharge tubing 202. It should be pointed out that the air pressure supplied through nozzle 194 is not critical as any air pressure supplied would rise in the airlift tubing and create the suction necessary. Higher air pressure, of course, produces greater suction effect.
Buoyancy
The buoyancy important to control the pressure of the apparatus upon the pipeline particularly, a pipeline having a corrosion coating is achieved through buoyancy tanks 12 and 14. Each of these tanks is secured to the apparatus by cradle struts 204 partially surrounding the buoyancy tanks and extending downwardly to support carriage 206. This carriage is suitably bolted at 208 to web 210 welded to the manifold 26. The buoyancy tanks 12 and 14 are so supported in the fore and aft locations to enable the buoyancy created by the buoyancy tanks to be effective in reducing the apparent weight of the underwater trenching apparatus.
The buoyancy tanks may be of any design and construction and preferably have water inlets at the bottom shown at 212 and air inlets at the top as shown at 214. The air inlets 214 may be connected to the manifold 26 to supply the air necessary to control the buoyancy of the tanks. Suitable protective bars 216 are provided to safeguard air inlets against damage.
As is known in the art, the tanks will readily fill with water upon submersion of the apparatus and upon opening of the air outlet valves 216. When the tanks are filled with water there would be no buoyant effect. But as the water is pumped out of the tanks the buoyant effect is evident with the maximum buoyancy obviously being achieved when all the water has been discharged.
Operation
The present underwater trenching apparatus is designed to create a trench T by cutting the formation from the bottom B of the body of water. The apparatus is self-propelled by the drive rollers 78, 80, 82 and 84 which grip the pipeline in driving engagement. In the event that there is an obstruction on the pipeline such as an anode A, as best shown in FIG. 4, the apparatus of this invention is able to override the obstruction even with the lack of any resilient mounting of the drive rollers on the apparatus.
Detection of the obstruction would be apparent from the signal received from the counter roller 156 that the apparatus has stopped and the fact that drive rollers would be spinning while in contact with the pipeline creating a wearing effect on the corrosion coating placed on the pipeline. Without the necessity of a diver in attendance to supervise the apparatus, the fore portions of the frame member 24 may be opened perhaps only a few inches by activating ram 42. Upon activation of the ram the fore portion of the frame member 24 pivots slightly in bearing 38 but also bends the upper and lower bars 34 and 36 slightly to create at this time greater separation or spacing between the fore portions of the frame members. Aft ram 44 maintains the aft portion of frame member 24 in contact with the aft abutment 52 and 54. The greater separation of the fore portions of the frame members also separates forward drive rollers 78 and 80 from driving engagement upon pipeline P. Pressure in feed hoses 102 and 106 is reduced, but fluid power is maintained to aft motors 92. In this case flow divider 96 directs sufficient fluid pressure to aft drive rollers 82 and 84 which alone are then capable of moving the underwater apparatus along the pipeline for a distance sufficient to enable forward disengaged drive rollers 78 and 80 to override the obstruction A. Upon passing the obstruction A in the pipeline surface, ram 42 is activated to close the fore portion of the frame member 24 to bring drive rollers 78 and 80 into full driving engagement.
Upon further movement of the apparatus along the pipeline rear drive rollers 82 and 84 can be expected to contact the same obstruction and the entire process repeated to open the aft portion of the frame member with ram 44 to disengage the aft drive rollers 82 and 84. Sufficient fluid pressure is maintained to forward drive rollers 78 and 80 to move the apparatus along the pipeline and permit aft disengaged drive rollers 82 and 84 to override the obstruction A. Upon the obstruction A being overriden by the disengaged aft drive rollers, ram 44 is activated to draw the aft portion of the frame together to contact the abutments 52 and 54 and bring the aft drive rollers in full drive engagement with the pipeline.
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This invention relates to the self-propelled underwater trenching apparatus and method for burying pipelines, cables and the like with minimum underwater diver supervision. The apparatus includes a frame having frame members positioned about the pipeline. Drive rollers are connected to the frame members for drive engagement with the pipeline. The frame members are movable about a pivot to selectively engage into or disengage rollers out of drive engagement with the pipeline. The apparatus also may include extensible means to move the pivot axis laterally or transversely of the pipeline. The formation is cut away by water jets secured to the apparatus to enable the pipeline to be buried in the trench formed. Upon meeting an obstruction on the surface of the pipeline, power rams in the fore portion of the frame member separate the frame member that may bend the frame member to bring the forward drive rollers out of driving engagement with the pipeline. The hydraulic propulsion system directs fluid flow to the aft drive rollers in driving engagement with the pipeline to move the apparatus forwardly until the forward drive rollers have overridden the obstruction. The sequence is reversed to utilize the forward drive rollers to move the apparatus along the pipeline until the aft drive rollers have overridden the pipeline.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process for drawing gel-spun polyethylene multi-filament yarns and to the drawn yarns produced thereby. The drawn yarns are useful in impact absorption and ballistic resistance for body armor, helmets, breast plates, helicopter seats, spall shields, and other applications; composite sports equipment such as kayaks, canoes, bicycles and boats; and in fishing line, sails, ropes, sutures and fabrics.
2. Description of the Related Art
To place the invention in perspective, it should be recalled that polyethylene had been an article of commerce for about forty years prior to the first gel-spinning process in 1979. Prior to that time, polyethylene was regarded as a low strength, low stiffness material. It had been recognized theoretically that a straight polyethylene molecule had the potential to be very strong because of the intrinsically high carbon—carbon bond strength. However, all then-known processes for spinning polyethylene fibers gave rise to “folded chain” molecular structures (lamellae) that inefficiently transmitted the load through the fiber and caused the fiber to be weak.
“Gel-spun” polyethylene fibers are prepared by spinning a solution of ultra-high molecular weight polyethylene (UHMWPE), cooling the solution filaments to a gel state, then removing the spinning solvent. One or more of the solution filaments, the gel filaments and the solvent-free filaments are drawn to a highly oriented state. The gel-spinning process discourages the formation of folded chain lamellae and favors formation of “extended chain” structures that more efficiently transmit tensile loads.
The first description of the preparation and drawing of UHMWPE filaments in the gel state was by P. Smith, P. J. Lemstra, B. Kalb and A. J. Pennings, Poly. Bull., 1, 731 (1979). Single filaments were spun from 2 wt. % solution in decalin, cooled to a gel state and then stretched while evaporating the decalin in a hot air oven at 100 to 140° C.
More recent processes (see, e.g., U.S. Pat. Nos. 4,551,296, 4,663,101, and 6,448,659) describe drawing all three of the solution filaments, the gel filaments and the solvent-free filaments. A process for drawing high molecular weight polyethylene fibers is described in U.S. Pat. No. 5,741,451. The disclosures of these patents are hereby incorporated by reference to the extent not incompatible herewith.
Although gel-spinning processes tend to produce fibers that are free of lamellae with folded chain surfaces, nevertheless the molecules in gel-spun UHMWPE fibers are not free of gauche sequences as can be demonstrated by infra-red and Raman spectrographic methods. The gauche sequences are kinks in the zig-zag polyethylene molecule that create dislocations in the orthorhombic crystal structure. The strength of an ideal extended chain polyethylene fiber with all trans —(CH 2 ) n —sequences has been variously calculated to be much higher than has presently been achieved. While fiber strength and multi-filament yarn strength are dependent on a multiplicity of factors, a more perfect polyethylene fiber structure, consisting of molecules having longer runs of straight chain all trans sequences, is expected to exhibit superior performance in a number of applications such as ballistic protection materials.
A need exists for gel-spun multi-filament UHMWPE yarns having increased perfection of molecular structure. One measure of such perfection is longer runs of straight chain all trans —(CH 2 ) n — sequences as can be determined by Raman spectroscopy. Another measure is a greater “Parameter of Intrachain Cooperativity of the Melting Process” as can be determined by differential scanning calorimetry (DSC). Yet another measure is the existence of two orthorhombic crystalline components as can be determined by x-ray diffraction. It is among the objectives of this invention to provide methods to produce such yarns by drawing, and the yarns so produced.
SUMMARY OF THE INVENTION
The invention comprises a process for drawing a gel-spun multi-filament yarn comprising the steps of:
a) forming a gel-spun polyethylene multi-filament feed yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents; b) passing the feed yarn at a speed of V 1 meters/minute into a forced convection air oven having a yarn path length of L meters, wherein one or more zones are present along the yarn path having zone temperatures from 130° C. to 160° C.; c) passing the feed yarn continuously through the oven and out of the oven at an exit speed of V 2 meters/minute wherein the following equations 1 to 4 are satisfied
0.25≦ L/V 1 ≦20, min Eq. 1
3≦ V 2 /V 1 ≦20 Eq. 2
1.7≦( V 2 −V 1 )/ L≦ 60, min Eq. 3
0.20≦2 L /( V 1 +V 2 )≦10, min. Eq. 4
The invention is also a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a peak value of the ordered-sequence length distribution function F(L) at a straight chain segment length L of at least 35 nanometers as determined at 23° C. from the low frequency Raman band associated with the longitudinal acoustic mode (LAM-1).
In another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dog, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a value of the “Parameter of Intrachain Cooperativity of the Melting Process”, ν, of at least about 535.
In yet another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein the intensity of the (002) x-ray reflection of one the filament of the yarn, measured at room temperature and under no load, shows two distinct peaks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is the low frequency Raman spectrum and extracted LAM-1 spectrum of filaments of a commercially available gel-spun multi-filament UHMWPE yarn (SPECTRA® 900 yarn).
FIG. 2( a ) is a plot of the ordered sequence length distribution function F(L) determined from the LAM-1 spectrum of FIG. 1 .
FIG. 2( b ) is a plot of the ordered sequence length distribution function F(L) determined from the LAM-1 spectrum of a commercially available gel-spun multi-filament UHMWPE yarn (SPECTRA® 1000 yarn).
FIG. 2( c ) is a plot of the ordered sequence length distribution function F(L) determined from the LAM-1 spectrum of filaments of the invention,
FIG. 3 shows differential scanning calorimetry (DSC) scans at heating rates of 0.31, 0.62 and 1.25°K/min of a 0.03 mg filament segment taken from a multi-filament yarn of the invention chopped into pieces of 5 mm length and wrapped in parallel array in a Wood's metal foil and placed in an open sample pan.
FIG. 4 shows an x-ray pinhole photograph of a single filament taken from multi-filament yarn of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In one embodiment, the invention comprises a process for drawing a gel-spun multi-filament yarn comprising the steps of:
a) forming a gel-spun polyethylene multi-filament feed yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents; b) passing the feed yarn at a speed of V 1 meters/minute into a forced convection air oven having a yarn path length of L meters, wherein one or more zones are present along the yarn path having zone temperatures from about 130° C. to 160° C.; c) passing the feed yarn continuously through the oven and out of the oven at an exit speed of V 2 meters/minute wherein the following equations 1 to 4 are satisfied
0.25≦ L/V 1 ≦20, min Eq. 1
3≦ V 2 /V 1 ≦20 Eq. 2
1.7≦( V 2 −V 1 )/ L≦ 60, min Eq. 3
0.20≦2 L /( V 1 +V 2 )≦10, min. Eq. 4
For purposes of the present invention, a fiber is an elongate body the length dimension of which is much greater than the transverse dimensions of width and thickness. Accordingly, “fiber” as used herein includes one, or a plurality of filaments, ribbons, strips, and the like having regular or irregular cross-sections in continuous or discontinuous lengths. A yarn is an assemblage of continuous or discontinuous fibers.
Preferably, the multi-filament feed yarn to be drawn comprises a polyethylene having an intrinsic viscosity in decalin of from about 8 to 30 dl/g, more preferably from about 10 to 25 dl/g, and most preferably from about 12 to 20 dl/g. Preferably, the multi-filament yarn to be drawn comprises a polyethylene having fewer than about one methyl group per thousand carbon atoms, more preferably fewer than 0.5 methyl groups per thousand carbon atoms, and less than about 1 wt. % of other constituents.
The gel-spun polyethylene multi-filament yarn to be drawn in the process of the invention may have been previously drawn, or it may be in an essentially undrawn state. The process for forming the gel-spun polyethylene feed yarn can be one of the processes described by U.S. Pat. Nos. 4,551,296, 4,663,101, 5,741,451, and 6,448,659.
The tenacity of the feed yarn may range from about 2 to 76, preferably from about 5 to 66, more preferably from about 7 to 51, grams per denier (g/d) as measured by ASTM D2256-97 at a gauge length of 10 inches (25.4 cm) and at a strain rate of 100%/min.
It is known that gel-spun polyethylene yarns may be drawn in an oven, in a hot tube, between heated rolls, or on a heated surface. WO 02/34980 A1 describes a particular drawing oven. We have found that drawing of gel-spun UHMWPE multi-filament yarns is most effective and productive if accomplished in a forced convection air oven under narrowly defined conditions. It is necessary that one or more temperature-controlled zones exist in the oven along the yarn path, each zone having a temperature from about 130° C. to 160° C. Preferably the temperature within a zone is controlled to vary less than ±2° C. (a total less than 4° C.), more preferably less than ±1° C. (a total less than 2° C.).
The yarn will generally enter the drawing oven at a temperature lower than the oven temperature. On the other hand, drawing of a yarn is a dissipative process generating heat. Therefore to quickly heat the yarn to the drawing temperature, and to maintain the yarn at a controlled temperature, it is necessary to have effective heat transmission between the yarn and the oven air. Preferably, the air circulation within the oven is in a turbulent state. The time-averaged air velocity in the vicinity of the yarn is preferably from about 1 to 200 meters/min, more preferably from about 2 to 100 meters/min, most preferably from about 5 to 100 meters/min.
The yarn path within the oven may be in a straight line from inlet to outlet. Alternatively, the yarn path may follow a reciprocating (“zig-zag”) path, up and down, and/or back and forth across the oven, around idler rolls or internal driven rolls. It is preferred that the yarn path within the oven is a straight line from inlet to outlet.
The yarn tension profile within the oven is adjusted by controlling the drag on idler rolls, by adjusting the speed of internal driven rolls, or by adjusting the oven temperature profile. Yarn tension may be increased by increasing the drag on idler rolls, increasing the difference between the speeds of consecutive driven rolls or decreasing oven temperature. The yarn tension within the oven may follow an alternating rising and falling profile, or it may increase steadily from inlet to outlet, or it may be constant. Preferably, the yarn tension everywhere within the oven is constant neglecting the effect of air drag, or it increases through the oven.
Most preferably, the yarn tension everywhere within the oven is constant neglecting the effect of air drag. The drawing process of the invention provides for drawing multiple yarn ends simultaneously. Typically, multiple packages of gel-spun polyethylene yarns to be drawn are placed on a creel. Multiple yarns ends are fed in parallel from the creel through a first set of rolls that set the feed speed into the drawing oven, and thence through the oven and out to a final set of rolls that set the yarn exit speed and also cool the yarn to room temperature under tension. The tension in the yarn during cooling is maintained sufficient to hold the yarn at its drawn length neglecting thermal contraction.
The productivity of the drawing process may be measured by the weight of drawn yarn that can be produced per unit of time per yarn end.
Preferably, the productivity of the process is more than about 2 grams/minute per yarn end, more preferably more than about 4 grams/minute per yarn end.
In another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from 5 dl/g to 35 dl/g, fewer than two methyl groups per thousand carbon atoms, and less than 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a peak value of the ordered-sequence length distribution function F(L) at a straight chain segment length L of at least 40 nanometers as determined at 23° C. from the low frequency Raman band associated with the longitudinal acoustic mode (LAM-1).
In yet another embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from 5 dl/g to 35 di/g, fewer than two methyl groups per thousand carbon atoms, and less than 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein filaments of the yarn have a value of the “Parameter of Intrachain Cooperativity of the Melting Process”, ν, of at least 535.
In a further embodiment, the invention is a novel polyethylene multi-filament yarn comprising a polyethylene having an intrinsic viscosity in decalin at 135° C. of from about 5 dl/g to 35 dl/g, fewer than about two methyl groups per thousand carbon atoms, and less than about 2 wt. % of other constituents, the multi-filament yarn having a tenacity of at least 17 g/d as measured by ASTM D2256-02, wherein the intensity of the (002) x-ray reflection of one filament of the yarn, measured at room temperature and under no load, shows two distinct peaks.
Preferably, a polyethylene yarn of the invention has an intrinsic viscosity in decalin at 135° C. of from about 7 dl/g to 30 dl/g, fewer than about one methyl group per thousand carbon atoms, less than about 1 wt. % of other constituents, and a tenacity of at least 22 g/d.
Measurement Methods
1. Raman Spectroscopy
Raman spectroscopy measures the change in the wavelength of light that is scattered by molecules. When a beam of monochromatic light traverses a semi-transparent material, a small fraction of the light is scattered in directions other than the direction of the incident beam. Most of this scattered light is of unchanged frequency. However, a small fraction is shifted in frequency from that of the incident light. The energies corresponding to the Raman frequency shifts are found to be the energies of rotational and vibrational quantum transitions of the scattering molecules. In semi-crystalline polymers containing all-trans sequences, the longitudinal acoustic vibrations propagate along these all-trans seqments as they would along elastic rods. The chain vibrations of this kind are called longitudinal acoustic modes (LAM), and these modes produce specific bands in the low frequency Raman spectra. Gauche sequences produce kinks in the polyethylene chains that delimit the propagation of acoustic vibrations. It will be understood that in a real material a statistical distribution exists of the lengths of all-trans seqments. A more perfectly ordered material will have a distribution of all-trans seqments different from a less ordered material. An article titled, “Determination of the Distribution of Straight-Chain Segment Lengths in Crystalline Polyethylene from the Raman LAM-1 Band”, by R. G. Snyder et al, J. Poly. Sci., Poly. Phys. Ed., 16, 1593–1609 (1978) describes the theoretical basis for determination of the ordered-sequence length distribution function, F(L) from the Raman LAM-1 spectrum.
F(L) is determined as follows: Five or six filaments are withdrawn from the multi-filament yarn and placed in parallel alignment abutting one another on a frame such that light from a laser can be directed along and through this row of fibers perpendicular to their length dimension. The laser light should be substantially attenuated on passing sequentially through the fibers. The vector of light polarization is collinear with the fiber axis, (XX light polarization).
Spectra are measured at 23° C. on a spectrometer capable of detecting the Raman spectra within a few wave numbers (less than about 4 cm −1 ) of the exciting light. An example of such a spectrometer is the SPEX Industries, Inc, Metuchen, N.J., Model RAMALOG® 5, monochromator spectrometer using a He—Ne laser. The Raman spectra are recorded in 90° geometry, i.e., the scattered light is measured and recorded at an angle of 90 degrees to the direction of incident light. To exclude the contribution of the Rayleigh scattering, a background of the LAM spectrum in the vicinity of the central line must be subtracted from the experimental spectrum. The background scattering is fitted to a Lorentzian function of the form given by Eq. 5 using the initial part of the Raman scattering data, and the data in the region 30–60 cm −1 where there is practically no Raman scattering from the samples, but only background scattering.
f ( x ) ) = H 4 · ( x - x 0 w ) 2 + 1 Eq. 5
where:
x 0 is the peak position H is the peak height w is the full width at half maximum
Where the Raman scattering is intense near the central line in the region from about 4 cm −1 to about 6 cm −1 , it is necessary to record the Raman intensity in this frequency range on a logarithmic scale and match the intensity recorded at a frequency of 6 cm −1 to that measured on a linear scale. The Lorentzian function is subtracted from each separate recording and the extracted LAM spectrum is spliced together from each portion.
FIG. 1( a ) shows the measured Raman spectra for a fibermaterial to be described below and the method of subtraction of the background and the extraction of the LAM spectrum.
The LAM-1 frequency, is inversely related to the straight chain length, L as expressed by Eq. 6.
L = 1 2 c ω L ( Eg c ρ ) 1 / 2 Eq. 6
where:
c is the velocity of light, 3×10 10 cm/sec ω L is the LAM-1 frequency, cm −1 E is the elastic modulus of a polyethylene molecule, g(f/cm 2 ρ is the density of a polyethylene crystal, g(m)/cm 3 g c is the gravitational constant 980 (g(m)−cm)/((g(f)−sec 2 )
For the purposes of this invention, the elastic modulus E, is taken as 340 GPa as reported by Mizushima et al., J. Amer. Chem., Soc., 71, 1320 (1949). The quantity (g c E/ρ) 1/2 is the sonic velocity in an all trans polyethylene crystal. Based on an elastic modulus of 340 GPa, and a crystal density of 1.000 g/cm 3 , the sonic velocity is 1.844×10 6 cm/sec. Making that substitution in Eq. 6, the relationship between the straight chain length and the LAM-1 frequency as used herein is express by Eq. 7.
L = 307.3 ω L , nanometers Eq . 7
The “ordered-sequence length distribution function”, F(L), is calculated from the measured Raman LAM-1 spectrum by means of Eq. 8.
F ( L ) = [ 1 - exp ( - hc ω L kT ) ω L 2 I ω ] , arbitrary units
where:
h is Plank's constant, 6.6238×10 −27 erg−cm k is Boltzmann's constant, 1.380×10 −16 erg/°K I ω is the intensity of the Raman spectrum at frequency ω L , arbitrary units
T is the absolute temperature, °K and the other terms are as previously defined.
Plots of the ordered-sequence length distribution function, F(L), derived from the Raman LAM-1 spectra for three polyethylene samples to be described below are shown in FIGS. 2( a ), 2 ( b ) and 2 ( c ).
Preferably, a polyethylene yarn of the invention is comprised of filaments for which the peak value of F(L) is at a straight chain segment length L of at least 45 nanometers as determined at 23° C. from the low frequency Raman band associated with the longitudinal acoustic mode (LAM-1). The peak value of F(L) preferably is at a straight chain segment length L of at least 50 nanometers, more preferably at least 55 nanometers, and most preferably 50–150 nanometers.
2. Differential Scanning Calorimetry (DSC)
It is well known that DSC measurements of UHMWPE are subject to systematic errors cause by thermal lags and inefficient heat transfer. To overcome the potential effect of such problems, for the purposes of the invention the DSC measurements are carried out in the following manner. A filament segment of about 0.03 mg mass is cut into pieces of about 5 mm length. The cut pieces are arranged in parallel array and wrapped in a thin Wood's metal foil and placed in an open sample pan. DSC measurements of such samples are made for at least three different heating rates at or below 2°K/min and the resulting measurements of the peak temperature of the first polyethylene melting endotherm are extrapolated to a heating rate of 0°K/min.
A “Parameter of Intrachain Cooperativity of the Melting Process”, represented by the Greek letter ν, has been defined by V. A. Bershtein and V. M. Egorov, in “Differential Scanning Calorimetry of Polymers: Physics, Chemistry, Analysis, Technology”, P. 141–143, Tavistoc/Ellis Horwod, 1993. This parameter is a measure of the number of repeating units, here taken as (—CH 2 —CH 2 —), that cooperatively participate in the melting process and is a measure of crystallite size. Higher values of ν indicate longer crystalline sequences and therefore a higher degree of order. The “Parameter of Intrachain Cooperativity of the Melting Process” is defined herein by Eq. 9.
v = 2 R T m1 2 Δ T m1 · Δ H 0 , dimensionless Eq. 9
where:
R is the gas constant, 8.31 J/°K-mol T m1 is the peak temperature of the first polyethylene melting
endotherm at a heating rate extrapolated to 0°K/min, °K
ΔT m1 is the width of the first polyethylene melting endotherm, °K ΔH 0 is the melting enthalpy of —CH 2 —CH 2 — taken as 8200 J/mol
The multi-filament yarns of the invention are comprised of filaments having a “Parameter of Intrachain Cooperativity of the Melting Process”, ν, of at least 535, preferably at least 545, more preferably at least 555, and most preferably from 545 to 1100.
3. X-Ray Diffraction
A synchrotron is used as a source of high intensity x-radiation. The synchrotron x-radiation is monochromatized and collimated. A single filament is withdrawn from the yarn to be examined and is placed in the monochromatized and collimated x-ray beam. The x-radiation scattered by the filament is detected by electronic or photographic means with the filament at room temperature (˜23° C.) and under no external load. The position and intensity of the (002) reflection of the orthorhombic polyethylene crystals are recorded. If upon scanning across the (002) reflection, the slope of scattered intensity versus scattering angle changes from positive to negative twice, i.e., if two peaks are seen in the (002) reflection, then two orthorhombic crystalline phases exist within the fiber.
The following examples are presented to provide a more complete understanding of the invention. The specific techniques, conditions, materials, proportions and reported data set forth to illustrate the principles of the invention are exemplary and should not be construed as limiting the scope of the invention.
EXAMPLES
Comparative Example 1
An UHMWPE gel-spun yarn designated SPECTRA® 900 was manufactured by Honeywell International Inc. in accord with U.S. Pat. No. 4,551,296. The 650 denier yarn consisting of 60 filaments had an intrinsic viscosity in decalin at 135° C. of about 15 dl/g. The yarn tenacity was about 30 g/d as measured by ASTM D2256-02, and the yarn contained less than about 1 wt. % of other constituents. The yarn had been stretched in the solution state, in the gel state and after removal of the spinning solvent. The stretching conditions did not fall within the scope of equations 1 to 4 of the present invention.
Filaments of this yarn were characterized by Raman spectroscopy using a Model RAMALOG® 5, monochromator spectrometer made by SPEX Industries, Inc., Metuchen, N.J., using a He—Ne laser and the methodology described herein above. The measured Raman spectrum, 1 , and the extracted LAM-1 spectrum for this material, 3 , after subtraction of the Lorenzian, 2 , fitted to the Rayleigh background scattering are shown in FIG. 1( a ). The ordered-sequence length distribution function, F(L), for this material determined from the LAM-1 spectrum and equations 7 and 8 is shown in FIG. 2( a ). The peak value of the ordered-sequence length distribution function, F(L), was at a straight chain segment length L of approximately 12 nanometers (Table I).
Filaments of this yarn were also characterized by DSC using the methodology described hereinabove. The peak temperature of the first polyethylene melting endotherm at a heating rate extrapolated to 0° K./min, was 415.4°K. The width of the first polyethylene melting endotherm was 0.9°K. The “Parameter of Intrachain Cooperativity of the Melting Process”, ν, determined from Eq. 9 was 389 (Table I).
A single filament taken from this yarn was examined by x-ray diffraction using the methodology described hereinabove. Only one peak was seen in the (002) reflection (Table 1).
Comparative Example 2
An UHMWPE gel-spun yarn designated SPECTRA® 1000 was manufactured by Honeywell International Inc. in accord with U.S. Pat. Nos. 4,551,296 and 5,741,451. The 1300 denier yarn consisting of 240 filaments had an intrinsic viscosity in decalin at 135° C. of about 14 dl/g. The yarn tenacity was about 35 g/d as measured by ASTM D2256-02, and the yarn contained less than 1 wt. % of other constituents. The yarn had been stretched in the solution state, in the gel state and after removal of the spinning solvent. The stretching conditions did not fall within the scope of equations 1 to 4 of the present invention.
Filaments of this yarn were characterized by Raman spectroscopy using a Model RAMALOG® 5, monochromator spectrometer made by SPEX Industries, Inc., Metuchen, N.J., using a He—Ne laser and the methodology described hereinabove. The ordered-sequence length distribution function, F(L), for this material determined from the LAM-1 spectrum and equations 7 and 8 is shown in FIG. 2( b ). The peak value of the ordered-sequence length distribution function, F(L), was at a straight chain segment length L of approximately 33 nanometers (Table I).
Filaments of this yarn were also characterized by DSC using the methodology described hereinabove. The peak temperature of the first polyethylene melting endotherm at a heating rate extrapolated to 0°K/min, was 415.2°K. The width of the first polyethylene melting endotherm was 1.3°K. The “Parameter of Intrachain Cooperativity of the Melting Process”, ν, determined from Eq. 9 was 466 (Table I).
A single filament taken from this yarn was examined by x-ray diffraction using the methodology described hereinabove. Only one peak was seen in the (002) reflection (Table 1).
Comparative Examples 3–7
UHMWPE gel spun yarns from different lots manufactured by Honeywell International Inc. and designated either SPECTRA® 900 or SPECTRA® 1000 were characterized by Raman spectroscopy, DSC, and x-ray diffraction using the methodologies described hereinabove. The description of the yarns and the values of F(L) and ν are listed in Table I as well as the number of peaks seen in the (002) x-ray reflection.
Example of the Invention
An UHMWPE gel spun yarn was produced by Honeywell International Inc. in accord with U.S. Pat. No. 4,551,296. The 2060 denier yarn consisting of 120 filaments had an intrinsic viscosity in decalin at 135° C. of about 12 dl/g. The yarn tenacity was about 20 g/d as measured by ASTM D2256-02, and the yarn contained less than about 1 wt. % of other constituents. The yarn had been stretched between 3.5 and 8 to 1 in the solution state, between 2.4 to 4 to 1 in the gel state and between 1.05 and 1.3 to 1 after removal of the spinning solvent.
The yarn was fed from a creel, through a set of restraining rolls at a speed (V 1 ) of about 25 meters/min into a forced convection air oven in which the internal temperature was 155±1° C. The air circulation within the oven was in a turbulent state with a time-averaged velocity in the vicinity of the yarn of about 34 meters/min.
The feed yarn passed through the oven in a straight line from inlet to outlet over a path length (L) of 14.63 meters and thence to a second set of rolls operating at a speed (V 2 ) of 98.8 meters/min. The yarn was cooled down on the second set of rolls at constant length neglecting thermal contraction. The yarn was thereby drawn in the oven at constant tension neglecting the effect of air drag. The above drawing conditions in relation to Equations 1–4 were as follows:
0.25≦[ L/V 1 =0.59]≦20,min Eq. 1
3≦[ V 2 /V 1 =3.95]≦20 Eq. 2
1.7≦[( V 2 −V 1 )/ L= 5.04]≦60, min Eq. 3
0.20≦[2 L /( V 1 +V 2 )=0.24]≦10, min Eq. 4
Hence, each of Equations 1–4 was satisfied.
The denier per filament (dpf) was reduced from 17.2 dpf for the feed yarn to 4.34 dpf for the drawn yarn. Tenacity was increased from 20 g/d for the feed yarn to about 40 g/d for the drawn yarn. The mass throughput of drawn yarn was 5.72 grams/min per yarn end.
Filaments of this yarn produced by the process of the invention were characterized by Raman spectroscopy using a Model RAMALOG® 5, monochromator spectrometer made by SPEX Industries, Inc., Metuchen, N.J., using a He—Ne laser and the methodology described hereinabove. The ordered-sequence length distribution function, F(L), for this material determined from the LAM-1 spectrum and equations 7 and 8 is shown in FIG. 2( c ). The peak value of the ordered-sequence length distribution function, F(L), was at a straight chain segment length L of approximately 67 nanometers (Table I).
Filaments of this yarn were also characterized by DSC using the methodology described hereinabove. DSC scans at heating rates of 0.31°K/min, 0.62°K/min, and 1.25°K/min are shown in FIG. 3 . The peak temperature of the first polyethylene melting endotherm at a heating rate extrapolated to 0°K/min, was 416.1°K. The width of the first polyethylene melting endotherm was 0.6°K. The “Parameter of Intrachain Cooperativity of the Melting Process”, ν, determined from Eq. 9 was 585 (Table I).
A single filament taken from this yarn was examined by x-ray diffraction using the methodology described hereinabove. An x-ray pinhole photograph of the filament is shown in FIG. 4 . Two peaks were seen in the (002) reflection.
TABLE I
L, nm
No. of
Ex. or
at
(002)
Comp.
Denier/
peak
ν,
X-Ray
Ex. No.
Identification
Fils
of F(L)
dimensionless
Peaks
Comp.
SPECTRA ®
650/60
12
389
1
Ex. 1
900 yarn
Comp.
SPECTRA ®
1300/240
33
466
1
Ex.2
1000 yarn
Comp.
SPECTRA ®
650/60
28
437
1
Ex. 3
900 yarn
Comp.
SPECTRA ®
1200/120
19
387
1
Ex. 4
900 yarn
Comp.
SPECTRA ®
1200/120
20
409
1
Ex. 5
900 yarn
Comp.
SPECTRA ®
1200/120
24
435
1
Ex. 6
900 yarn
Comp.
SPECTRA ®
1300/240
17
467
1
Ex.7
1000 yarn
Exam-
Inventive
521/120
67
585
2
ple
Fiber
It is seen that filaments of the yarn of the invention had a peak value of the ordered-sequence length distribution function, F(L), at a straight chain segment length, L, greater than the prior art yarns. It is also seen that filaments of the yarn of the invention had a “Parameter of Intrachain Cooperativity of the Melting Process”, ν, greater than the prior art yarns. Also, this appears to be the first observation of two (002) x-ray peaks in a polyethylene filament at room temperature under no load.
Having thus described the invention in rather full detail, it will be understood that such detail need not be strictly adhered to but that further changes and modifications may suggest themselves to one skilled in the art, all falling with the scope of the invention as defined by the subjoined claims.
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Gel-spun multi-filament polyethylene yarns possessing a high degree of molecular and crystalline order, and to the drawing methods by which they are produced. The drawn yarns are useful in impact absorption and ballistic resistance for body armor, helmets, breast plates, helicopter seats, spall shields, and other applications; composite sports equipment such as kayaks, canoes, bicycles and boats; and in fishing line, sails, ropes, sutures and fabrics.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a National Stage of International Application No. PCT/IB2006/050605 filed on Feb. 27, 2006, claiming priority based on Portugal Patent Application No. 103265, filed Apr. 22, 2005, the contents of all of which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to microcapsules for smart textile materials and the application processes for such microcapsules.
BACKGROUND OF THE INVENTION
The microcapsules are applied to fibres in textile articles known as smart textiles, to impart a controlled release of different products such as fragrances, antibacterial, insecticides, antioxidants, vitamins or durable materials to impart functions, such as thermal insulation and thermal comfort as in the case of microcapsules of PCM (phase change materials). They are also used as special effects materials, as it is the case of photochromic or thermochromic pigments that change colour according to luminosity or temperature, respectively. The binding of microcapsules to the fibres is usually done with thermoplastic binders or with glue (sizing operation). The production of microcapsules of the controlled release type with polymers, is, for example, described in patent GB1371179 of 1974. PCM microcapsules have normally walls made of polymers obtained by the condensation polymerization of urea-formaldehyde and melamine-formaldehyde, given that these materials are very resistant to temperature and to chemical agents and solvents. Other condensation polymers are used, like polyamide and polyurethane, but they are not appropriate for PCM given that they are not sufficiently resistant. They are only appropriate for the release of the active product since they rupture easily. Other microcapsules also for temporary use on products to be used next to the skin are made of biocompatible products such as chitosan, a product obtained from crab or other crustaceous species.
The application of controlled release microcapsules with binders or with glue during sizing textile processing started in the 1970's. The problem with this form of binding microcapsules is that they come off easily during the washing of the textile article or other processes that involve friction forces, given that they do not have a durable bond with the fibre. This way, the desired effect of the microcapsules is quickly lost by wearing the textile article.
It is therefore convenient that the bonds between fibres and microcapsules be resistant to multiple domestic washing, according to the most recent washing standards. The microcapsules for the controlled release of fragrances, antibacterial agents, insect repellents and other active products, are normally applied in such a way so as to be exposed to friction and so rupturing and releasing the products, such as printing with thermoplastic polymers. They can also be applied by glued padding with binders in pad-mangle machines. Normally they are not applied by exhaustion processes given that they have no affinity towards the fibres. Even if they are applied by exhaustion process, the fabric or knitwear still needs to be padded with binders and the microcapsules subsequently fixed by the thermoplastic binder at high temperatures, in appropriate machines, normally a stenter.
PCM (phase change materials) microcapsules on the other hand should not rupture and are normally applied immersed in a coating or foam constituted of thermoplastic polymers. First, the microcapsules are dispersed in a binder and are then bound to the fibres by a thermal process after coating the material with a ruler or rollers. On non-woven it can be done by spraying or by padding followed by thermal fixation in a roller-machine (foulard), always mixed with binders, being one of the corresponding patents from 1994 (U.S. Pat. No. 5,366,801). The thermal process of thermoplastic fusion of the binder containing the microcapsules with the fibres, is usually realized in a continuous drying and curing machine of the type of a stenter used in textile finishing, or under pressure in a heated calendar rollers, at a temperature higher than the melting point of the thermoplastic binder. Given that the quantity of PCM microcapsules is much higher than in the case of the other microcapsules, normally between 30 and 100% of the weight of the fibre, the quantity of binder is also higher. In this case, the durability of the microcapsules is not an issue, since they are totally involved by a film or coating of binder. Phase Change Materials (PCM) are materials that change phase from solid to liquid and from liquid to solid, with the characteristic that and in doing so they absorb great quantities of energy by changing from solid to liquid and releasing great quantities of energy by changing from liquid to solid. Their energy retention characteristics can also be used as a self-regulation of temperature within pre-defined limits, such as, for example, to convey comfort to the wearer of winter clothing and winter footwear. Given that the direct application of PCM microcapsules on yarns, woven fabrics and knitwear present problems, namely technical ones the more usual applications resort to supports, such as polyurethane foam containing PCM microcapsules, or woven or non-woven materials coated with thermoplastic binders containing PCM microcapsules as referred in U.S. Pat. No. 5,851,338. These supports are then incorporated in clothing or footwear articles. They can also be incorporated in composite materials, such as the ones mentioned in U.S. Pat. No. 6,004,662. PCM microcapsules are usually made of polymers, such as urea-formaldehyde or melamine-formaldehyde.
DESCRIPTION
In the invention we are proposing, the microcapsules do not need binder to fix on the fibres, since they contain reactive groups that are going to react with the fibres. The set of direct bonds between individual microcapsules and the fibres present several advantages in relation to the use of binders containing microcapsules, given that the coatings with binders have many disadvantages, causing namely a loss of flexibility of the textile materials, a higher impermeability to perspiration, causing this way discomfort, and in materials that are in contact with the skin, they cause a harsh handle.
The main objective of the invention we claim, is to avoid the disadvantages caused by the use of binders, trough the direct bond of the microcapsules on the fibres, through chemical bond that also conveys a durability to wear and washing. The chemical bonds are obtained through the introduction of functional groups in the microcapsules that bind chemically to functional groups of the fibres. The chemical bonds can be ionic or, better still, covalent, where a simple chemical reaction takes place by addition or substitution, promoted solely by the pH of the solution, normally alkaline, or resorting to initiators in case of an addition radical reaction, since these bonds are more resistant and since they guarantee the permanence of microcapsules on the fibres even when subjected to physical processes involving friction forces, or chemical processes such as domestic and industrial washing, in washing machines, or dry-cleaning.
In this invention that we propose, microcapsules can be applied without binder, by padding process followed by the passing of the fabric or knitwear through the squeezing rollers. In the case of materials that cannot be padded such as lofty non-woven, the microcapsules are applied by spray. In both processes, padding or spraying, it is still necessary that the chemical reaction takes place at room temperature or at a hot temperature. In the case of reaction at room temperature, the reaction needs a lot more time to occur, being the process similar to the Pad-batch process used for reactive dyes. In case of a process with heating, it is usually applied in a dryer or stenter, a process also used reactive dyes denominated ‘Pad-fix’ or ‘Pad-cure’. Another problem of existing microcapsules is that there is no affinity between the microcapsules and the fibres, mainly because there are no attraction forces, such as ionic or polar Van der Waal's forces such as those existing between dyes and fibres, nor is there formation of a strong chemical bond of the covalent type between the microcapsules and the fibres, which means that the microcapsules have to be applied together with thermoplastic binder by printing, or by padding processes with binder and passage through squeeze rollers and finally thermally fixed. In this invention we also propose the use of microcapsules with functional groups that impart affinity towards the fibres, and that can be applied by exhaustion processes and the groups react with the fibres during the exhaustion process, without being necessary to fix them later with binder in a padding and curing machine. Exhaustion processes are applied in machines in which the material moves in the liquor (bath) without resorting to squeeze rollers, the material being transported by mechanical action and also supported by the movements of the liquor itself. In this liquor it is normally introduced the dye and the auxiliary products necessary for the preparation and dyeing of the material. In this case, before, during or after the dyeing, the microcapsules are introduced into the liquor and, due to their affinity, they adhere to the textile material throughout the process. Examples of these machines are the ‘jet’ and progressive flow machines used in the dyeing of woven and knitted fabrics and domestic and industrial washing machines. These machines are appropriate for woven and knitted fabrics and, in the domestic and industrial washing machines, microcapsules can be applied to garments and other finished textile articles. For yarns there are special machines that make the liquor circulate through the yarn, which is in the form of bobbin or skein.
The ionic forces that are formed by attraction of opposite charges, cause the microcapsules to have affinity towards the fibres and may therefore be applied by exhaustion processes.
In case of fibres with cationic charges, for example polyamide fibres when in acid conditions, negative charges are introduced into the microcapsules which will impart affinity and a strong bond between microcapsules and fibres. Other groups, such as epoxy groups, convey affinity towards the fibres through polar forces.
In the case of cellulosic fibres, the process is similar to the dyeing process with reactive dyes. Just as with dyes, microcapsules should have groups that convey affinity towards the fibres and can react with the hydroxyl groups of the cellulose.
Microcapsules with functional groups have the additional advantage of being able to be dyed at the same time as the fibres, in the same colour, and in this way the original white colour of the microcapsules will not be seen, which in the case of PCM microcapsules is relevant since they are used in large quantities so as to produce the desired effect, and so they would be noticed otherwise. Dyes should be dyes with affinity towards the microcapsules and/or dyes with a group capable of reacting with the functional group of the microcapsules.
The microcapsules for controlled release of fragrances, antibacterial agents, insect repellent and other active products, are usually applied so that they are exposed to friction to subsequently rupture and to release the products, for example by printing with thermoplastic binders. They can also be applied in fine textiles by padding with a binder, in machines with squeezing rollers. Normally they are not applied by exhaustion process, since they do not have affinity for the fibres. Even if they are applied by exhaustion process, the woven or knitted fabric needs to be padded with a binder and the microcapsules later thermally bound by the thermoplastic binder at high temperatures, in an appropriate machine, usually a stenter. In the invention we are proposing, the set of direct bonds between individual microcapsules and the fibres has several advantages relatively to the use of binding materials containing microcapsules since the use of binders has many disadvantages other than the lack of durability of the microcapsules to friction and washes, causing namely a lack of flexibility of the textile materials, a higher impermeabilization to transpiration, causing therefore discomfort, and in materials in contact with the skin they cause a harsh handle. In this process that we are claiming, microcapsules are chemically bound to the fibres without resorting to binders. The durability of the microcapsules is higher than that of the process of application by binding microcapsules with binders. In this invention that we are claiming, instead of the usage of binders that fix onto fibres, microcapsules containing functional reactive groups are used, binding the microcapsules directly to the fibres. The functional groups are introduced into the microcapsules of urea-formaldehyde, melamine-formaldehyde, polyamide or chitosan, reacting with the amino (NH 2 ) or hydroxyl (OH) groups present in these microcapsules. As an alternative, microcapsules, for example, with a second shell on top of the urea or melamine-formaldehyde shell can be used, made of polymers containing functional groups, poly (glycidyl methacrylate) or any other polymer that may contain epoxy (glycidyl) groups, polyacrylic acid containing carboxylic groups, or other polymers that can react with epoxy groups that form the bond with the fibre, when added jointly with the microcapsules in the application process to the fibre, such as poly(methacrylic acid) or derivatives, that contain carboxylic groups (—COOH), for example, being the binding group a polyglycidyl, containing two or more epoxy groups. This group is particularly useful, once it can react with an epoxy group of a ‘bridging’ product containing two or more epoxy groups, leaving the other epoxy group free to react with the fibre.
For microcapsules with two polymers, being the outer layer functional, it is, for example, possible to use microcapsules of melamine-formaldehyde coated with a vinyl polymer, where the monomer used for forming the polymer contains a functional group that will form ionic bonds with the fibres, or groups that react with the fibres, such as the epoxy group, alkyls with a halogen substitution, like for example ethyl chlorine, vinyl groups, heterocycles, for example.
In case of intending to use only the microcapsule with the layer of urea-formaldehyde, melamine-formaldehyde, polyamide or chitosan, the introduction of functional groups, such as epoxy groups or ethyl chlorine, for example, will be done through a reaction between the amine groups that do not react with the formaldehyde, or hydroxyl groups, and therefore remaining free, with bifunctional compounds that contain epoxy groups, alkyl groups substituted with a halogenous, vinyl groups, heterocyclics, remaining the other group free for reacting with the fibre.
It is convenient that the bonds between the fibres and the microcapsules are resistant to multiple domestic washing, according to the requirements of the most recent washing standards. This is the main objective of the invention we are claiming. In the cellulosic fibres this resistance is conferred, for example, by the irreversible covalent bond that is formed between the epoxy group present in the shell of the microcapsule and the cellulosate groups of ionised cellulose (cel-O − ). This reaction should be carried out in alkaline conditions so that ionization of the cellulose occurs with the formation of the cellulosate groups. Another group that can be introduced in the microcapsules that reacts with the cellulose fibres can be the —CO—CH═CHR group, where R can be a hydrogen or a halogen. The reaction can be a nucleophilic addition reaction with the cellulosate ion in alkaline conditions or a radical addition reaction with the hydroxyl group of the cellulosic fibre, in the presence of an initiator. Another group can be the —CO—(CH 2 ) n Cl group, that reacts by nucleophilic substitution with the cellulosate ion of cellulose in alkaline conditions.
In case of polyamide and wool fabrics, it is the amine groups that react with the epoxy groups, —CO—CH═CHR, dichlorotriazine or the —CO—(CH 2 ) n Cl group of the microcapsules. In these cases the reaction occurs in slightly acid, neutral or basic conditions.
In the case of acrylic fibres, the sole shell or the outer shell, has as functional group the quaternary ammonium salt group, —N + (R) 3 , where R is an alkyl group, that will link through an ionic bond to the anionic groups present in the fibres.
Instead of the microcapsules reacting directly with the fibres, a ‘bridging’ group can be used between the microcapsules and the fibre can be used, being the microcapsules and bridging groups applied simultaneously. These are bifunctional compounds with two of the reactive groups already mentioned, epoxy, —CO—CH═CHR, dichlorotriazine or —CO—(CH 2 ) n Cl, one reacting with the microcapsule and the other with the fibre, forming that way a binding bridge between the microcapsules and the fibre. Another group can be ethylene imine, similar to epoxy once it is also a highly unstable and reactive ring, reacting in a similar way by an attack from the cellulosate ion of the cellulose, opening the ring during the reaction.
Next, examples are given of the previous preparation of microcapsules with reactive groups by reaction with one of the bifunctional groups, as well as of the simultaneous application of the bifunctional product and the microcapsules during the application process of the microcapsules on the fibre.
EXAMPLE 1
Preparation of PCM Microcapsules with an Outside Shell of poly(glycidyl methacrylate)
100 g of PCM microcapsules were added to 1000 ml of water. The microcapsules were dispersed by agitation. Next, glycidyl methacrilate monomer and potassium persulfate were added. Temperature was raised up to 90° C. and was kept for two hours at this temperature. Afterwards, the microcapsules were filtered, washed and dried in an oven at 60° C.
EXAMPLE 2
A mixture of 50 g/L of PCM microcapsules with an outer shell of poly(glycidyl methacrylate), 2.75 g/L of sodium hydroxide were applied by exhaustion, in a machine with liquor circulation and fabric movement, to a sample of 5 Kg of bleached jersey cotton knitwear, with a liquor ratio of 1:10 and a temperature of 75° C. for 30 minutes. The samples was then rinsed and dried at 120° C.
EXAMPLE 3
Preparation of PCM Microcapsules with an Outside Shell of poly(glycidyl methacrylate)
100 g of PCM microcapsules were added to 1000 ml of water. The microcapsules were dispersed by agitation. Next, acid methacrylic monomer and potassium persulphate were added. Temperature was raised up to 90° C. and was kept for two hours at this temperature. Afterwards, the microcapsules were filtered, washed and dried in an oven at 60° C.
EXAMPLE 4
A mixture of 50 g/L of PCM microcapsules with an outer shell of poly(acid acrylic acid), 25 g/L epichlorydrin, 2.75 g/L of sodium hydroxide were applied by exhaustion, in a machine with liquor circulation and fabric movement, to a sample of 5 Kg of bleached jersey cotton knitwear, with a liquor ratio of 1:10 and a temperature of 75° C. for 30 minutes. The samples was then rinsed and dried at 120° C.
EXAMPLE 5
A mixture of 50 g/L of PCM microcapsules with an outer shell of poly(glycidyl methacrylate), 25 g/L of epichlorydrin, 2.75 g/L of sodium hydroxide were applied by exhaustion, in a machine with liquor circulation and fabric movement, to a sample of 5 Kg of bleached jersey cotton knitwear, with a liquor ratio of 1:10 and at a temperature of 75° C. for 30 minutes. The samples was then rinsed and dried at 120° C.
EXAMPLE 6
A mixture of 50 g/L of PCM microcapsules of poly(methacrylic acid), 25 g/L of ethylene glycol di-glycidyl ether were applied by exhaustion, in a machine with liquor circulation and fabric movement, to a sample of 5 Kg of polyamide jersey knitwear, with a liquor ratio of 1:10 and a temperature of 75° C. for 30 minutes. The samples was then rinsed and dried at 120° C.
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Microcapsules for smart textile materials, containing an active product and with reactive groups, with the objective of chemically binding the microcapsules to the fibers. The microcapsules contain active products such as PCM (phase change materials), or can be of controlled release of products such as fragrances, essential oils, antibacterial and others with the objective to add specific functional properties to the textile materials. They can be applied by padding and spraying followed by thermofixation. In case of products such as knitwear the application process can also be by exhaustion process, given that the microcapsules acquire affinity towards the fibers and react with the fibers during the process. The chemical bond of the controlled release microcapsules with the fibers confers them a higher resistance to washing than the existing microcapsules glued to the fabric by printing or padding.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Non-Provisional application Ser. No. 12/317,576 filed Dec. 26, 2008 which claims benefit of U.S. Provisional application No. 61/008,931 filed on Dec. 26, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention represents a significant step forward in the field of friction control materials by replacing the use of the stop-start and reciprocating needle punch tacking operation with a continuous, rotary motion polymer bonding layer operation that decreases cost and increases the longitudinal strength of the composite by maintaining original fiber orientation in the direction parallel to the long sides of the sheet.
[0007] Currently marketed friction and anti-friction parts sold for the purpose of slowing/stopping a moving surface or allowing unimpeded movement of a moving surface do not address the problems of high capital equipment cost, slower than achievable manufacturing rates, inability to rapidly and economically adapt manufacturing to desired results.
[0008] All friction and anti-friction materials, if properly described should be easily categorized into one of five categories, as follows; 1). Sintered metallic, 2). Molded Composite, 3). Wet-laid papermaking techniques, 4). Woven textile composite, 5). Dry-laid, wet-laid, or polymer-laid nonwoven textile composite. This latter of which will henceforth be defined “Category 5 Composites”.
[0009] The term “Bonding Layer” is herein defined as polymer resin or polymer resin composite. The term “Matrix” is herein defined as a continuous film and discontinuous island matrix. The term “Tacking” is herein defined as solidifying the Matrix to form a blanket.
[0010] The scope of this invention is specifically addressed to the production of non-woven textile employed as a raw material in the manufacture of friction and anti-friction composites, and therefore discussion of all other friction and anti-friction material prior art not employing non-woven textile composites are beyond the scope of this invention and are not addressed herein.
[0011] 2. Description of Related Art
[0012] Prior art within the arena of friction and anti-friction non-woven textile composite materials is extremely limited from a patent and public record perspective. The following art is representative of what is published.
[0013] U.S. Pat. No. 5,646,076 and U.S. Pat. No. 5,989,375 to inventor Bortz discloses a friction controlling device that has a low wear rate, non-abrasive operational characteristics and unique construction materials. However, the disclosure of inventor Bortz lacks a solution to the problems of slow production speed, high production cost, inability to rapidly and economically adapt manufacturing to desired results largely due to the application of the needle-punching as the sole means to bind fibrous webs into a unitary structure or blanket, which is then employed as the fibrous starting material to produce friction or anti-friction composite.
[0014] U.S. Pat. No. 6,835,448 to inventor Menard discloses a friction material that has a stable frictional coefficient in lubricated environments, improved resistance to heating and stability at high operational pressures. However, the disclosure of inventor Menard lacks a solution to the problems of slow production speed, high production cost, inability to rapidly and economically adapt manufacturing to desired results, which like Bortz, is largely due to the application of the needle-punching as the sole means to bind fibrous webs into a unitary structure or blanket, which is then employed as the fibrous starting material to produce friction or anti-friction composite.
[0015] U.S. Pat. No. 5,546,880 to inventor Ronyak discloses a annular filamentary structure that has a simplified method of substrate manufacture. However, the disclosure of inventor Ronyak lacks a solution to the problems of slow production speed, high production cost, inability to rapidly and economically adapt manufacturing to desired results once again due largely to the application of the needle-punching as the sole means to bind fibrous webs into a unitary structure or blanket, which is then employed as the fibrous starting material to produce friction or anti-friction composite.
[0016] U.S. Pat. No. 5,609,770 to inventor Bazshushtari discloses a carbon/carbon composite that has a novel method of allowing recycling of scrap raw materials. Carbon vapor deposition (CVD) and equivalents thereof or saturation with a resin transformable into carbon at high temperature is employed to fill voids between the fibers, forming a composite. Although the inherent efficiency gains of employing a rotary needle-punch loom compared to a flat needle-punch board are described. However, the disclosure of inventor Bazshushtari lacks a solution to the problems of slow production speed, high production cost, inability to rapidly and economically adapt manufacturing to desired results once again due largely to the application of the needle-punching as the sole means to bind fibrous webs into a unitary structure or blanket, which is then employed as the fibrous starting material to produce friction or anti-friction composite.
[0017] Further U.S. Pat. No. 3,950,599 to Board, Jr. describes a low friction laminate liner for bearings which employs a needle-punched non-woven textile backing material bonded to an anti-friction fluoro-polymer surface material. This non-woven backing material is not engaging any moving surfaces, and therefore the non-woven component is irrelevant from a prior art perspective concerning this invention.
[0018] None of the above patents or Published patent applications singly or in combination is seen to describe the present invention as claimed.
BRIEF SUMMARY OF THE INVENTION
[0019] The present invention is a composite for friction and anti-friction applications. Generally, the instant invention solves the problem of expensive production by allowing significant improvements in line speed, reduced capital machinery expense and reduced labor costs.
[0020] An embodiment of the present invention discloses a new and unique process for economical manufacture of composite material used for controlling the frictional properties between relatively moving surfaces. The new and unique process begins with supplying a first layer and a second layer of fibers comprising an Aramid or Ultra High Molecular Weight Polyethylene UHMWPE, material wherein the fibers are nonwoven and of a first down web, cross web and through web orientation, un-sized and are surface activated. A second step involves supplying a bonding material comprising a granular form of a synthetic polymer resin wherein the particle size of the granular form is in the range of 5 micrometers to 260 micrometers and the particle shape of the granular form is irregular with a melting point of the synthetic polymer is 55 degrees Celsius to 130 degrees Celsius. After the material is supplied the instant invention discloses applying a discontinuous bonding layer of the bonding material to the first layer comprising spraying the bonding material on one or more of the first layer or second layer wherein spraying is directed at one or more of the first or second layers and the sprayed bonding layer is deposited in a non-uniform pattern. This is followed by tacking the first layer to the one or more second layers comprising the step of bringing surfaces to be tacked together into alignment and contact and melting the bonding layer by one of the methods taken from the list: a. heat, b. pressure, c. both heat and pressure while the fibers are maintained at a first down web (orientation parallel to the edge of the mat), cross web (orientation perpendicular to the edge of the mat) and through web orientation (orientation perpendicular to the face of the mat therefore eliminating disturbed orientation due to needle punching operations), followed by applying saturation resin to the nonwoven textile to displace void volume to displace void volume, yielding a saturated nonwoven textile. The process of the present invention continues by drying the saturated nonwoven textile with heat, RF energy or heat and RF energy, yielding a composite board. This in turn is followed by compressing the composite board with pressure and or heat to reduce porosity yielding a densified composite board, curing under the influence of heat yields the finished product—a finished composite material.
[0021] In addition to solving these problems added features that allow process parameters to be rapidly adjusted to decrease labor required to perform manufacturing adjustments, decrease capital equipment cost for manufacturing adjustments, decrease capital equipment downtime for manufacturing adjustments, decreased rate of machinery malfunction and decreased labor to remedy machinery malfunctions are also provided.
[0022] The preferred embodiment of the present invention provides additional unique features by providing unique ability to contour/profile inter-laminar properties within the z-axis thickness of the composite material, allow discreet covert incorporation of product identification tracers and allow maximum flexibility of desired manufacturing parameters to optimize varying product applications.
[0023] The primary objective of the present invention is to reduce manufacturing costs associated with prior art.
[0024] A further objective of the present invention is to apply advanced features allowing more manufacturing flexibility than possible using prior art.
[0025] It is an objective of the present invention to reduce manufacturing cost provide more efficient manufacture of a non-woven textile unitary structure or blanket by reducing labor cost and tooling cost associated with mechanical techniques of bonding fibrous webs into said unitary structure or blanket, thereby reducing overall raw material cost (RMC).
[0026] It is a further objective of the present invention to improve ease of processing, performance and create a competitive edge by incorporating new manufacturing techniques to provide the ability to optimize desired physical and non-physical properties which were previously unattainable when employing mechanical techniques to bond fibrous webs into a unitary structure or blanket.
[0027] It is a feature of the present invention to further reduce cost by employing easily applied bonding layers to bond multiple layers of fibrous webs together into a non-woven textile unitary structure or blanket to reduce labor cost and tooling cost associated with mechanical techniques of bonding said fibrous webs into said unitary structure or blanket, thereby reducing overall raw material cost (RMC).
[0028] It is a further feature of the present invention to reduce cost and ease further processing by employing bonding layers which are easily varied in surface coverage percent to quickly modify stiffness or hand of the resulting unitary structure or blanket with reduced labor and tooling costs associated with employing said modifications upon mechanical entanglement web bonding machinery.
[0029] It is a further feature of the present invention to reduce cost, ease further processing and allow tailored properties of finished products when the top, bottom and center layer are the friction surface by employing new manufacturing techniques by incorporating a mask similar to silk-screening used in the printing industry, or electrostatic methods to selectively deposit bonding layers in a pre-determined pattern onto multiple layers of fibrous webs being bound together into a non-woven unitary structure or blanket to optimize desired physical properties while minimizing raw material cost (RMC).
[0030] It is a further feature of the present invention to reduce cost, ease further processing and allow tailored properties of finished products when the top, bottom and center layer are the friction surface by employing new manufacturing techniques by incorporating a mask similar to silk-screening used in the printing industry, or electrostatic methods to selectively deposit chemical treatments in a pre-determined pattern to attract or repel later application of bonding layers onto multiple layers of fibrous webs being bound together into a non-woven unitary structure or blanket to optimize desired physical properties while minimizing raw material cost (RMC).
[0031] It is a further feature of the present invention to create a competitive edge over prior art by employing new manufacturing techniques by incorporating product identification tracers into Bonding Layer bonding layers in discrete and covert ways which are difficult to detect, duplicate or reverse engineer to optimize desired non-physical properties of said unitary structure or blanket.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0032] FIG. 1 : Is a top view of the continuous film matrix.
[0033] FIG. 2 : Is a top view of the discontinuous island matrix.
[0034] FIG. 3 : Is a block diagram of the process of the preferred embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The present invention is a composite for friction and anti-friction applications. Generally, the instant invention solves the problem of expensive production by allowing significant improvements in line speed, reduced capital machinery expense and reduced labor costs. In addition to solving these problems added features that allow process parameters to be rapidly adjusted to decrease labor required to perform manufacturing adjustments, decrease capital equipment cost for manufacturing adjustments, decrease capital equipment downtime for manufacturing adjustments, decreased rate of machinery malfunction and decreased labor to remedy machinery malfunctions are also provided.
[0036] The preferred embodiment of the present invention provides additional unique features by providing unique ability to contour/profile inter-laminar properties within the z-axis thickness of the composite material, allow discreet covert incorporation of product identification tracers and allow maximum flexibility of desired manufacturing parameters to optimize varying product applications.
[0037] The present invention includes a friction or anti-friction composite raw material comprised of fibrous webs held together into a unitary structure, or blanket, without the need for mechanical bonding methods, such as needle-punching, stitch-bonding or spunlaced hydro-entanglement textile techniques.
[0038] The present invention makes use of Bonding Layer, either in a Matrix, to bond a plurality of webs together into a unitary structure or blanket which is employed as an application-specific raw material used in the manufacture of nonwoven based friction and anti-friction products, and has commercially important advantages to offer the friction and anti-friction industries, and also friction and anti-friction product consumers, as follows; 1). Lower cost of manufacture because of increased line speed compared to needle-punched or spunlaced hydro-entanglement nonwoven production techniques, 2). No possibility of broken or pulled steel needles from a needle-loom or needle-board becoming embedded in the unitary structure or blanket, avoiding abrasive spots in finished friction or anti-friction composite when manufacturing a product advertised as non-abrasive, 3). Maximum control of the percentage of web surfaces bonded together without time-consuming tooling changes, 4). Ability to quickly customize and profile the amount of individual interlaminar web bonding properties required from the unitary structure or blanket for each particular friction or anti-friction application the material is intended for, 5). Maximum control of raw-material-cost (RMC) and cost versus benefit ratio for each friction or anti-friction application by adjusting the Bonding Layer formula and percentage of surface coverage of the Matrix, 6). Using product identification tracers in the Matrix polymer resin composite gives the ability to discretely and covertly hide product identification tracers within the interlaminar structure of the overall friction or anti-friction composite, keeping them hidden from the eye of others, and making said product identification tracer technologies more difficult to detect, duplicate, or reverse engineer, 7). Ability to accurately control stiffness, or what is referred to as “hand” in the textile industry, of the unitary structure or blanket by adjusting the formulation and percentage of the Matrix Bonding Layer to provide best results using widely varied manufacturing machinery and methods, 8). Ability to quickly change application technique (for example changing from powder spraying to powder sprinkling) in the event of malfunctioning application equipment applying the Matrix where no replacement part for the present application technique is immediately available, thus avoiding costly downtime. The same cannot be said if you break your last needle-board or needle-roll in a needle-punching operation and do not have another replacement part immediately available, 9). Ability to customize the absorption profile of said unitary structure or blanket perpendicular to the plane of the blanket in the Z-axis thickness direction by manipulating percentage and pattern of surface coverage of said Matrix independently for each individual web layer, allowing controlled amounts of Bonding Layer to enter each respective web layer upon saturation of the overall unitary structure or blanket, based upon the principle of volumetric displacement. Increased volume percentage of Matrix within some web layers forming the unitary structure or blanket will reduce the volume of Bonding Layer allowed to enter these respective webs during subsequent saturation of the overall unified structure or blanket, and likewise, decreased volume percentage of Matrix within other web layers will produce the opposite effect. Ability to manipulate such interlaminar Matrix Bonding Layer to saturation Bonding Layer ratios can be beneficial by allowing the outer surface of the overall friction or anti-friction composite to contain larger percentages of less expensive Matrix Bonding Layer, because the outermost surface will be machined away in subsequent manufacturing operations, thereby lowering overall raw-material-cost (RMC). This technique will also allow the lowest web layers of the overall friction or anti-friction composite located closest the bonding interface with the pad, disc or shoe core, typically made of steel or other materials, to be adjusted to provide optimum physical properties for best possible adhesion and other desirable properties at the bonding interface, such as flexure. Such profiling of interlaminar properties is not possible with any mechanical bonding techniques such as needle-punching, stitch-bonding or spunlaced hydro-entanglement techniques.
[0039] The present Invention, depending upon polymer type and polymer solvent selected, and whether or not photo-initiators are incorporated, said Bonding Layer forming the Matrix may be cured or dried quickly in a continuous process using conveyorized ultraviolet light curing or conveyorized radio frequency drying techniques if curing or drying is required of the selected polymer type to solidify the Matrix of the unitary structure or blanket prior to proceeding further in the manufacturing process.
[0040] Web-Bonding Matrix Resins
[0041] The present invention employs a relatively diverse set of possible polymer resins to be used alone or in compatible mixtures, and may be used to formulate polymer resin composite to form the Matrix bonding said webs together. The reason for such a diverse set of polymer types is because this invention may employ such a diverse set of fiber types, and is capable of producing a friction composite raw material which is application-specific for almost any intended friction application manufacturing process.
[0042] THERMOPLASTICS may include acrylic, ethylene vinyl acetate (EVA), polyamide, polyamide-imide (PAI), polyimide, polyethylene, polypropylene, polyester, vinylester, polycarbonate, polyvinyl chloride (PVC), polyaryl ether, polyetherimide, and polyphenyl sulfide.
[0043] Polyamide (nylon) may include low molecular weight nylons such as polycaprolactone and polycaprolactan. These have the lowest melting points of any thermoplastics are particularly useful to bond webs of fibers which are heat sensitive, and to generally minimize heat cycle process times with any fiber type, thereby maximizing line speed.
[0044] Polyethylene may include maleated polyethylene waxes, oxidized polar polyethylene waxes, and metallocene polyethylenes. These all have low melting temperatures which are generally desirable for web bonding purposes to keep heating cycle times to a minimum, and prevent damage to some fiber types.
[0045] Polypropylene may include high molecular weight polypropylene.
[0046] Polyester may include polybutylene terephthalate (PBT) and cyclic polybutylene terephthalate (CBT). Although CBT may be employed as the only resin, the high cost of CBT may prohibit this for economic reasons. CBT flows extremely well upon melting, with very low viscosity. Also, tin catalyst may be employed with CBT to break open the cyclic molecular structure upon melting to transform CBT into PBT. However, the cyclic CBT resin also is useful as a rheological flow enhancer when used as a minor additive in conjunction with other compatible polymers, and is therefore also listed within the section on rheology modifiers in this invention. Typical use of CBT as a flow enhancer ranges from about 1 to 10 percent by weight of CBT powder blended with other polymer powders.
[0047] Some thermoplastics may be blended with heat-sensitive cross-linkers to render them thermosets.
[0048] ELASTOMERS may include natural rubber, polybutadiene, polyisoprene, polyurethane elastomers, polysulfide polymers, polychloroprene, ethylene-propylene copolymers, ethylenepropylene-diene terpolymers, chlorosulfonated polyethylene, and plasticized polyvinylchloride.
[0049] THERMOPLASTIC ELASTOMERS may include styrene-butadiene (SB), styrene-isoprene (SI), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-ethylene/butylene (SEB), styrene-ethylene/propylene (SEP), styrene-ethylene/butylene-styrene (SEBS), and styrene-ethylene/propylene-styrene (SEPS).
[0050] THERMOSETS may include acrylic, melamine, phenolic, polyamide, polyamide-imide (PAI), polyimide, polyester, vinylester, and urethane.
[0051] Phenolic may include resol water emulsion (SPhG).
[0052] Some factors to be considered when selecting polymer resin types to be employed as the Matrix polymer resin or to formulate polymer resin composite employed as either said matrix include temperature resistance, thermal conductivity, abrasion resistance, composition of opposing surface, abrasivity upon opposing surface, chemical and environmental resistance, compatibility with other polymer resins in a mixture, compatibility with fiber types to be used, compatibility with powder or small fiber modifiers to be included in formulating a polymer resin composite, application ease and efficiency, temperature required for complete melt, sharpness of melt point or narrowness of melt range, desired thickness of unitary structure or blanket, time duration of heating cycle required for complete melt in central core of unitary structure or blanket, storage stability of polymer resin raw materials, viscosity of melted solids in liquid state, viscosity of solids dissolved in solvent, strength and tenacity of bonding upon selected fiber types, wetting action upon selected fiber types, ease of equipment cleanup, ease of fabrication, amount of waste created in fabrication, disposal restrictions on polymer resin waste and associated solvents, health hazards of polymer resins and associated environmental controls, health hazards of solvents employed in liquid polymer resin systems and associated environmental controls, flammability hazards of fine powders and associated controls, flammability of solvents employed in liquid polymer resin systems and associated controls, commercial availability of desired grades, stability and reliability of supply chains, raw-material-cost (RMC), marketability of friction product produced, place and price point of friction product within the overall friction market, anticipated sales volume of friction product, and anticipated profit margin on sales. The later of these are business-oriented goals, as opposed to technical-oriented goals, but can affect the polymer resin types selected nevertheless.
[0053] Fibers
[0054] The present invention employs a relatively diverse set of possible fibers to form said webs. The reason for such a diverse set of fiber types is because this invention is capable of producing a friction composite raw material which is application-specific for almost any intended friction application manufacturing process.
[0055] Polymer fibers, natural plant fibers, natural animal fibers, glass fibers, natural mineral fibers, man-made mineral fibers (MMMF), ceramic fibers, metallic fibers, semi-metallic fibers, carbon fibers, and carbon fiber precursors may all be successfully employed in this invention. These nonwoven webs may be composed of short-chop fibers, staple fibers longer than one-half inch in length, or tows of continuous fibers. Staple fibers are preferred because of their ease of processing into nonwoven webs.
[0056] Polymer fibers, which may include, aramid fibers, novoloid fibers, polybenzimidazole (PBI) fibers, polyamide fibers, and fluoropolymer fibers.
[0057] Natural plant fibers, which may include hemp fibers, cotton fibers, jute fibers, coconut fibers, sisal fibers, ramie fibers, kenauf fibers, flax fibers, banana leaf fibers, and abaca fibers.
[0058] Natural animal fibers, which may include wool.
[0059] Glass fibers, which may include E-glass and S-glass.
[0060] Natural mineral fibers, which may include wollastonite.
[0061] Man-made mineral fibers (MMMF), which may include rockwool.
[0062] Ceramic fibers.
[0063] Metallic fibers, which may include copper, copper alloys, aluminum, aluminum alloys, and steel.
[0064] Semi-metallic fibers, which are metal-coated plastic, plastic-coated metal, and a core completely covered by metal.
[0065] Carbon fibers.
[0066] Carbon fiber precursors, which may include polyacrylonitrile (PAN) fiber, oxidized polyacrylonitrile fiber (OPF), and novoloid fiber.
[0067] Some factors to be considered when selecting fiber types to be employed include temperature resistance, thermal conductivity, abrasion resistance, composition of opposing surface, abrasivity upon opposing surface, chemical and environmental resistance, compatibility with other fibers in a mixture, compatibility with polymer resin to be used, compatibility with powder or small fiber modifiers incorporated into polymer resin to be used, ease of fabrication, affinity of bonding to selected resin types, ability to be easily wetted by selected polymer resin type, amount of fiber waste created in fabrication, disposal restrictions on fiber waste, health hazards and associated environmental controls, flammability hazards and associated controls, commercial availability of desired grades, stability and reliability of supply chains, raw-material-cost (RMC), marketability of friction product produced, place and price point of friction product within the overall friction market, anticipated sales volume of friction product, and anticipated profit margin on sales. The later of these are business-oriented goals, as opposed to technical-oriented goals, but can affect the fiber types selected nevertheless.
[0068] Natural plant and animal fibers make use of “green technologies” for friction applications.
[0069] Natural plant and animal fiber nonwoven textiles commercially available to date are all bonded using mechanical entanglement techniques. No effort in the natural textile industry has focused upon binding said webs of natural fibers together using polymer bonded web techniques using Bonding Layer, and the many advantages such polymer bonded web techniques offer beyond those of mechanical entanglement techniques, such as needle-punching and spunlaced hydro-entanglement techniques.
[0070] Powder Application of Web-Bonding Matrix Resins
[0071] Although application of said Matrix Bonding Layer may be accomplished using almost any logical method, the preferred method of application for discontinuous island matrix Bonding Layer is using electrostatic powder spray techniques. Commercially available equipment is available from Nordson Corporation (Westlake, Ohio, USA).
[0072] The preferred embodiment of said Bonding Layer powders used to produce said discontinuous island matrix is for direct electrostatic application on the carding line after producing a carded web, with or without pre-heating of said web, and with or without post-heating the applied powder, but prior to crosslapping. Because polymer resin powder or polymer resin composite powder is applied to only one side of the fibrous web prior to crosslapping, upon crosslapping, the respective alternating pockets of crosslapped web now alternate between being rich in powder content for one crosslap web pocket and being deficient in powder content for the next successive crosslap web pocket. However, the end of the crosslapping line is incorporated with heaters (preferably in the form of a convection tunnel oven with impingement airflows for relatively thick blanket thickness, or an array of infrared heaters for relatively thin blanket thickness, depending on the overall thickness of webs being bonded) to pre-melt all polymer resin powder or polymer resin composite powder used in said discontinuous island matrix to a temperature greater than the melting point of such powders within the internal core of the web blanket, and then the output of said crosslapping line proceeds directly into heated calendar rolls to maintain heat and produce sufficient pressure to force an equilibrium of molten powder islands between the alternating resin-rich and resin-deficient crosslap web pocket zones, resulting in uniform interlaminar bonds between all web layers within the resulting unitary structure or blanket.
[0073] The advantages of using electrostatic powder application techniques over other methods include the following;
[0074] No application messy liquids, foams, pastes or gels is required. These can gum-up the carding line and require periodic cleaning from machinery. Electrostatic powders can be easily removed from carding line and crosslapping line machinery using vacuum or compressed air. No need to dry solvent used in liquids, foams, pastes or gels prior to crosslapping the treated webs. This saves time, capital machinery expense, electricity consumption, and eliminates associated safety and environmental concerns regarding volatile solvent emissions. No need to pre-bond webs to a film prior to crosslapping, or to insert film into web crosslaps. This is a relatively slow procedure which a given film thickness can easily place somewhat more or less polymer resin between the webs than is needed to achieve the desired interlaminar web bonding strength. In-situ changes of polymer resin quantity for a particular production run often requires using a film of another thickness, which requires additional raw materials inventory for films of differing thickness. Also, polymer resin composite of custom formulation is not easy or economical to produce into a film. Powder retains electrostatic attraction to webs during the crosslapping process, and does not fall away during the crosslapping process as with powders applied by gravity sprinkling techniques.
[0075] Successful use of electrostatic powder techniques requires that the selected polymer resin or formulated polymer resin composite must be relatively dry, and must be presented to the powder spray or fluidized bed application apparatus in the form of powders with a particle size distribution profile suitable for the powder application equipment used. Such polymer materials may be available in suitable form which is ready-to-use as supplied, or may need to be milled and classified for particle size prior to use. Fiber or particulate modifier components used to formulate said polymer resin composite will likely need to be pre-dispersed in a liquid solution of the selected polymer resin, and subsequently spray-dried into a powder, or otherwise solidified into larger solids which can subsequently be milled into a powder. Although many milling techniques may be employed to reduce larger size Bonding Layer materials to powder, the preferred milling technique employs cryogenic milling using a rotary hammer mill, of the swinging-hammer type, with nitrogen cooling gas. Rotary hammer mills are generally the most efficient and economical mill types for the widest variety of cryogenic fine-milling applications, although disc mills and jet mills generally have the ability to cryogenically mill even finer particle sizes for any given material, with jet mills being the finest. In cryogenic milling, a supply of cooling gas is necessary within the hammer mill to keep internal mill temperatures sufficiently low to prevent subject Bonding Layer from fusing within the mill, and to maintain milling temperatures below the glass transition temperature (Tg) of the Bonding Layer being milled. Subsequent screen classification to remove oversize particles may be employed using various rotary, vibratory or air classification techniques. Even at cryogenic milling temperatures, polymers with friable or brittle mechanical properties can be milled to smaller particle sizes than polymers with flexible or resilient mechanical properties. The most efficient mill type depends upon the type of material being milled, and the desired particle size. The desired or optimum particle size of a given polymer material may not be economically or physically achievable. For example, some of the more resilient polymers, such as low melting temperature metallocene polyethylenes, polyethylene waxes, polypropylene waxes, elastomers, thermoplastic elastomers, and low molecular weight nylons such as polycaprolactones and polycaprolactans may be difficult to cryogenically mill to a particle size below about 60 mesh (250 micrometers), which is relatively large, and may require multiple types of mills to be employed in succession. Other more friable polymers may easily be milled to incredibly small particle sizes beyond the smallest ASTM standard sieve size of 635 mesh (20 micrometers) by employing only a hammer mill. There are no easy generalized rules about mill or classification equipment selection, and all depends upon the type and specific properties of material being milled, particle size desired, and narrowness of particle size distribution profile desired.
[0076] Spray-dried powders, which are Bonding Layer dissolved in solvent as a liquid and subsequently spray-dried is also possible to be usefully employed in this invention, but such techniques are also limited on attainable particle size without employing additional milling and classification, depending upon the polymer resin selected, and the type and size of any fine fibers or particulates employed as modifiers in formulating said polymer resin into a polymer resin composite.
[0077] Contract toll-milling and classification services are also available from companies such as Prater Industries (Bolingbrook, Ill., USA), CCE Technologies (Cottage Grove, Minn., USA), ICO Polymers (Asbury, N.J., USA), and Aveka, Inc. (Saint Paul, Minn., USA). Prater and CCE also manufacture various types of mills and classifiers. Given the broad possibilities of commercially available polymer resins which may be successfully employed in this invention for said discontinuous island matrix, contract toll-processing can be a very economical alternative to be considered carefully because toll-processors have diverse expertise in milling and particle size classifying of almost infinitely varied materials, and the proper machinery to most efficiently do so.
[0078] Typical powders for electrostatic application are typically in the 10 to 30 micrometer range, which means the particles will pass through at least 450 mesh screen (32 micrometer), and possibly as fine as 635 mesh screen (20 micrometer) ASTM standard sieve sizes. Finer particle sizes are attainable for some relatively friable polymers, possibly down to 5 micrometers or less, but these cannot be classified by screen because 635 mesh is the finest ASTM screen size available, and therefore such powders must be air-classified.
[0079] Powder application to non-electrically conductive webs of most polymer fibers typically require what is known in the powder industry as a “tribo gun” for successful powder application, wherein a triboelectric charge is imparted due to the nature of the gun construction materials, and the velocity and force of particle impact upon such gun materials. Typically, polyamide (nylon) or fluoropolymer (Teflon, PTFE) spray gun construction materials will inherently impart the desired charge necessary for sprayed powders to be attracted to various non-electrically conductive webs. In the case of spraying polyethylene powder, a gun constructed of nylon would be used. Electrically conductive webs of most metallic and carbon fibers can have powder successfully applied with traditional corona (powered) or tribo (non-powered) powder spray equipment.
[0080] Many factors will determine how the electrostatic powder web-coating process is most successfully and efficiently completed. Variables include particle size distribution profile and electrical conductivity properties of the selected polymer resin powder or formulated polymer resin composite powder, electrical conductivity properties of the fibrous web said powder is being applied to, temperature of fibrous webs, air pressure supplied to the powder spray gun or fluidized bed, feed rate of powder supply feeder, gun spray pattern, distance between gun and target web surface, quality of cathode (negative ground) connection to surfaces supporting the web, materials web supporting surfaces are constructed of, electrostatic voltage potential imparted upon the powder particles within the corona (powered) or tribo (non-powered) spray apparatus, and the option of heating the powder coated webs on the carding line after powder application to melt applied powder onto said webs, thereby preventing said powders from falling off in the subsequent crosslapping process, although additional heating after crosslapping will be required to bond crosslapped webs into a unitary structure or blanket. Virtually any dry polymer compound of proper particle size, regardless of electrical conductive properties, or a lack thereof, may be applied using electrostatic powder methods at the relatively short application distances used herein.
[0081] The aforesaid effect of web temperature upon powder retention efficiency is an interesting aspect of said electrostatic powder deposition techniques. Webs slightly pre-heated, but below the melting temperature of the polymer resin powder or polymer resin composite powder, will exhibit greater powder retention, with less corresponding overspray loss of powder to other non-web machine and plant areas when compared to relatively cooler ambient temperature webs.
[0082] The present invention is intended to produce a relatively thick unitary structure or blanket which requires bonding many layers of webs using a Matrix composed of Bonding Layer. Powders applied directly to webs are of a polymer type designed to be melted to cause bonding of said webs by formation of a discontinuous island matrix, and therefore the time required to obtain a uniform and homogeneous heat profile throughout the entire blanket thickness to obtain uniform melting of said matrix polymers will increase as blanket thickness increases, and is a function of time, temperature, blanket thickness, blanket density, airflow velocity, and airflow profile. In the case of a tunnel oven on the crosslapping line, the function of time may be increased by either slowing the system line speed or increasing the length of the heated zone. The other remaining aforesaid factors may be adjusted also. Temperature, pressure, and speed of heated calendar rolls which the unitary structure or blanket enters upon exiting the crosslapping line oven must also be considered and adjusted carefully to obtain the desired results.
[0083] Any suitable Bonding Layer may be applied to said webs as a powder to form a discontinuous island matrix, or said powder may be dissolved in a suitable solvent to form a solution for coating, spraying or dipping said webs, evaporating said solvent from said web coating, and thereby used to create a continuous film or discontinuous island matrix. A wide variety of meltable polymer resins within the thermoplastic, elastomer, and thermoplastic elastomer polymer groups are commercially available, and may be successfully processed and employed for subject powders and other application methods. The type of meltable polymer resin selected for use as a web bonding matrix material in general, and for producing powders specifically, should be selected from polymer types which melt at reasonably low temperatures to facilitate rapid and efficient melting, and to keep melt temperatures below the temperature compatibility of the fibers composing the fibrous webs being bonded into the unitary structure or blanket. Fibers types with relatively high temperature compatibility are generally non-meltable, and may allow selection of almost any meltable polymer resin deemed to be chemically compatible with the fibers and economically feasible for production of the desired unitary structure or blanket. Fiber types which are meltable require careful selection of only polymer resins having very low melting temperatures to avoid melting the fibers during the web bonding process.
[0084] Polyethylene powders are among the most economical from a raw-material-cost (RMC) perspective, and will generally have lower melting temperatures than polypropylene powders. Many polyethylene powders have melting temperatures as low as about 95 degrees C. or about 203 degrees F.
[0085] One manufacturer of cryogenically ground thermoplastic polyethylene (PE) and polypropylene (PP) polymer powders is Innotek, LLC (Big Springs, Tex., USA). The powders they offer are typically below 212 micrometers (pass 70 mesh screen ASTM standard sieve size), but smaller custom milled sizes are available.
[0086] Polymer resins of the thermoplastic elastomer family which are commercially available and well suited for this application include several polymer groups and chemical family designations. Many of these polymers contain molecules composed of combinations of block segments of styrene (thermoplastic) monomer units and rubber (elastomer) monomer units in various ratios and molecular arrangements, thus are classified in the broadest sense as thermoplastic elastomers. Some examples are styrene-butadiene (SB), styrene-isoprene (SI), styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-ethylene/butylenes (SEB), styrene-ethylene/propylene (SEP), styrene-ethylene/butylene-styrene (SEBS), and styrene-ethylene/propylene-styrene (SEPS). The later 2 groups (SEBS and SEPS) generally have higher melting temperatures than the others as general classes. One commercially available polymer within the SIS group with exceptionally low melting temperature range is Kraton D1162BT available from Kraton Polymers, LLC (Houston, Tex., USA).
[0087] Flame spray is also an alternative technique of powder coating. This involves blowing the employed Bonding Layer powder through a propane flame so as pre-melted liquid droplets are delivered to the target surface, similar to electrostatic application of liquid paints, except without solvent. Alternatively, flame spray techniques may be employed by flame spraying said Bonding Layer powder at a temperature slightly below the melting point of the powder, and pre-heating the target web surface to a temperature above the melting point of said powder, whereby said powder melts rapidly upon contact with said target web surface. For some other applications, the advantage of flame spray techniques is that no post-heating is required to melt the powder, allowing substrates that will not tolerate heat well, such as wood, to be coated in a solvent-free manner. However, the present invention requires the plurality of webs to be bonded simultaneously into a unitary structure or blanket after crosslapping. Therefore, even if flame spray were used to deposit the subject discontinuous island matrix of Bonding Layer upon subject webs on the carding line, heat would still be required after crosslapping to re-melt the discontinuous island matrix and thereby affect a bond between the plurality of crosslapped web layers to produce the desired unitary structure or blanket. As a result, heat upon the crosslapped stack of webs will be required for electrostatic powders to produce the desired web-bonding results in producing a unitary structure or blanket, regardless of how the powder is conveyed to the webs, liquid or solid. Some disadvantages of flame spray techniques are the relatively large amounts of overspray loss of sprayed material, and the relatively large amounts of polymer burned and thereby consumed by the flame.
[0088] General Production Issues
[0089] The melting temperature of Bonding Layer employed to form said Matrix is of importance to reduce the length of heating time required to melt such materials within subject webs to increase production speed and reduce associated machinery size and capital expense. This is also important if bonding webs of meltable fibers, where Bonding Layer forming the Matrix must melt well below the melting temperature of the web fibers. The melting temperature of some low molecular weight nylons, such as polycaprolactones and polycaprolactans are lower than any other useable materials able to form said Matrix, and melt as low as about 55 to 60 degrees C. or about 131 to 140 degrees F., with exceptionally sharp melting points. The melting temperature ranges of all other useable polymers for creating the Matrix will be higher than the aforementioned low molecular weight nylons, but many other polymer types are commercially available with relatively low melting temperatures. Some examples of relatively low melting temperature polymers are metalocene polyethylenes, polyethylene waxes, polyethylene powders, and some thermoplastic elastomers. The melting temperature range of thermoplastic elastomers can vary greatly, depending on the molecular block configuration and the thermoplastic to elastomer block ratio, and will always be a relatively broad temperature range, without a sharp melting point. Polyethylene powders have melting temperatures as low as about 95 degrees C. or about 203 degrees F., which may be below the melting temperature of some webs composed of meltable fibers. Other webs composed of non-meltable fibers may employ virtually any meltable Bonding Layer which has a melting temperature below temperatures which may damage or decompose said web fibers. As can be seen, carefully selected melting temperatures of polymers employed for the polymer resin or to formulate polymer resin composite have implications concerning viability and efficiency of the web bonding process, whether applied dry as a powder to create a discontinuous island matrix, or dissolved in a suitable solvent to form a solution suitable to spray or dip said webs, evaporating said solvent from said web coating, and thereby used to create a continuous film or discontinuous island matrix. This later technique is not generally as desirable because it adds additional steps to the manufacturing process, and raises other concerns such as environmental VOC emissions, toxicity, and flammability. Similar solvent techniques may also be employed to create gels, foams, or pastes of Bonding Layer which may also be successfully employed.
[0090] For the intended friction composite application, the interlaminar bond strength between said webs comprising the resulting unitary structure, or blanket is of little importance once said unitary structure, or blanket is subsequently saturated with other Bonding Layer and dried to form a rigid composite board. Only sufficient interlaminar bond strength between said webs of the unitary structure, or blanket to hold said webs together during the subsequent saturation and drying process is required.
[0091] The interlaminar strength of the webs which compose the resulting unitary structure or blanket is greatly influenced by many factors, such as the type of web fiber selected, type of polymer resin selected, modifiers selected if polymer resin was formulated into a polymer resin composite, volumetric percentage of Bonding Layer employed, pattern and uniformity of Matrix application to the web surfaces, and if only one side of the crosslapped webs had Bonding Layer applied, the efficiency of melt flow, fiber wetting, and pressure applied by heated calendar rolls to affect good penetration of melted material through the webs in resin-rich crosslap pockets into adjacent resin-deficient crosslap pockets. Because the intent of the present invention is to subsequently saturate the resulting unitary structure or blanket with other Bonding Layer, or for subsequent carbon vapor deposition (CVD) to produce a rigid composite board suitable for manufacturing friction control devices, it is desired that the unitary structure or blanket maintain sufficient flexibility and porosity to facilitate subsequent saturation or carbon vapor deposition (CVD) while simultaneously providing sufficient temporary interlaminar strength between the webs to facilitate such subsequent blanket saturation or carbon vapor deposition (CVD). The temporary interlaminar strength provided to the resulting unitary structure or blanket must also be able to withstand the forces applied in ruled-edge die cutting, whereby the unitary structure or blanket is pre-cut to the desired shape or preform prior to saturation with other Bonding Layer, or subjected to carbon vapor deposition (CVD).
[0092] Modifiers
[0093] Modifiers and their Applications;
[0094] The general term MODIFIERS are classified herein as friction modifiers, thermal conductivity modifiers, rheology modifiers, product identification tracers, fillers, and colors. Nano-materials have been incorporated into the aforementioned 6 groups according to their useful functionality (if any) when said modifiers are used as additives to the selected polymer resin for the purpose of formulating a polymer resin composite. The present invention employs a relatively diverse set of possible modifiers to be used alone or in compatible mixtures, and may be incorporated into said polymer resin to formulate a polymer resin composite employed to form the Matrix bonding said webs together. The reason for such a diverse set of modifier types is because this invention may employ such a diverse set of fiber types, polymer resin types, and is capable of producing a friction composite raw material which is application-specific for almost any intended friction application manufacturing process.
[0095] FRICTION MODIFIERS are employed to manipulate the frictional coefficient higher or lower as desired to obtain the desired frictional properties in a friction or anti-friction material. Anti-friction materials are designed to reduce frictional coefficient as low as possible within the desired temperature range. Friction materials are designed to increase and maintain frictional coefficient to a desired level within the desired temperature range. In the case of fiber-resin composites, the inherent frictional coefficient of a pure fiber-resin system without friction modifiers and within the desired temperature range is governed by the fiber type, resin type, fiber to resin ratio, and density of the composite. Although frictional coefficient of the overall pure fiber-resin system may be considered, often such fibers and resins are selected upon specific criterion, such as abrasion resistance, raw material cost (RMC), manufacturing cost, efficiency of manufacturing, and abrasiveness of the composite upon opposing frictional surfaces. Such fiber and resin selection does not often yield a composite with the desired frictional coefficient. It is almost always desirable to adjust this inherent frictional coefficient of the selected pure fiber-resin system either higher or lower, depending upon the intended product application. Friction modifiers, usually and most easily incorporated into the resin component of the fiber-resin composite system, are what allows this inherently limited window of frictional coefficient to become a much more dynamically modified window of frictional coefficient possibilities for a given fiber-resin system. The term FRICTION MODIFIERS as used herein are small particulates of about 500 microns or less in diameter, or small fibers of about 1 millimeter or less in length, or combinations thereof, which are incorporated into said polymer resin to formulate a polymer resin composite employed to form the disMatrix intended to bond subject webs together. Particulates or fibers employed as friction modifiers are sub-classified under the following sub-groups for simplicity; nano-materials, carbon materials, polymer materials, semi-metallic materials, metallic materials, metal soaps, natural materials, very hard man-made materials, and micro-spheres. NANO-MATERIALS are defined as carbon nano-fibers, single-wall carbon nano-tubes, multi-wall carbon nano-tubes, nano-clay and nano-silica. CARBON MATERIALS are defined as graphite, calcined petroleum coke, carbon black, and carbon fiber. POLYMER MATERIALS are defined as natural rubber, synthetic rubber, polyamide, olefins including polyethylene and polypropylene, and fluoropolymer. SEMI-METALLIC MATERIALS are defined as metal-filled fluoropolymer (more than 50% fluoropolymer), fluoropolymer-filled metal (more than 50% metal), metal-coated plastic, plastic-coated metal, or a core completely covered by metal. METALLIC MATERIALS are defined as copper, copper alloys, lead, lead alloys, tin, tin alloys, antimony, antimony alloys, iron, and steel. METAL SOAPS are defined as aluminum stearate, calcium stearate, lithium stearate, magnesium stearate, zinc stearate. NATURAL MATERIALS are defined as mica, feldspar, calcium carbonate (limestone), clay, wollastonite, diatoms, silica, aluminum oxide (corundum) (Al203), zinc oxide (ZnO), barium sulfate (BaO4S), molybdenum disulfide (MoS2), and lead sulfide (galena) (PbS). VERY HARD MAN-MADE MATERIALS are defined as chromium carbide (Cr2C2), chromium oxide (Cr2O3), molybdenum carbide (Mo2C), tantalum carbide (TaC), tantalum niobium carbide (TaNbC), titanium boride (TiB2), titanium nitride (TiN), titanium carbide/nitride (TiCN), tungsten carbide (WC), tungsten sulfide (WS2), tungsten titanium carbide (WTiC), tungsten tantalum carbide (WTaC), tungsten titanium tantalum carbide (WTiTaC), boron carbide (B4C), hexagonal boron nitride (HBN), and silicon carbide (SiC). MICRO-SPHERES are defined as glass micro-spheres (derived from flyash or man-made), and resol micro-spheres.
[0096] THERMAL CONDUCTIVITY MODIFIERS are employed to manipulate thermal conductivity higher or lower as desired, although increasing thermal conductivity is typically the intended goal. In a friction material such as a brake or clutch assembly, or an anti-friction material such as a journal bearing or thrust bearing, it is typically desirable to transfer frictionally created heat away from the friction surface, into lower layers of the friction material, and most preferably completely out of the friction material by transferring such heat into other core materials which support the friction or anti-friction facing. In the case of fiber-resin composites, the inherent thermal conductivity of a pure fiber-resin system without thermal conductivity modifiers is governed by the fiber type, resin type, fiber to resin ratio, and density of the composite. Although thermal conductivity of the overall pure fiber-resin system may be considered, often such fibers and resins are selected upon specific criterion, such as abrasion resistance, raw material cost (RMC), manufacturing cost, efficiency of manufacturing, and abrasiveness of the composite upon opposing frictional surfaces. Such fiber and resin selection does not often yield a composite with the desired thermal conductivity. It is almost always desirable to adjust this inherent thermal conductivity of the selected pure fiber-resin system either higher or lower, depending upon the intended product application. Thermal conductivity modifiers, usually and most easily incorporated into the resin component of the fiber-resin composite system, are what allows this inherently limited window of thermal conductivity to become a much more dynamically modified window of thermal conductivity possibilities for a given fiber-resin system. The term THERMAL CONDUCTIVITY MODIFIERS as used herein are small particulates of about 500 microns or less in diameter, or small fibers of about 1 millimeter or less in length, or combinations thereof, which are incorporated into said polymer resin to formulate a polymer resin composite employed to form the disMatrix intended to bond subject webs together. Particulates or fibers employed as thermal conductivity modifiers are sub-classified under the following sub-groups for simplicity; nano-materials, carbon materials, metallic materials, and semi-metallic materials. NANO MATERIALS are defined as carbon nano-fibers, single-wall carbon nano-tubes, multi-wall carbon nano-tubes, nano-clay and nano-silica. CARBON MATERIALS are defined as graphite, calcined petroleum coke, carbon black, and carbon fiber. METALLIC MATERIALS are defined as copper, copper alloys, and iron. SEMI-METALLIC MATERIALS are defined as metal-coated plastic, plastic-coated metal, or a core completely covered by metal.
[0097] RHEOLOGY MODIFIERS are used to selectively control the flow of liquid components within a liquid system. This includes solids which are subsequently melted to become liquids temporarily. Viscosity is only one form of rheology modification. Other methods of rheology modification include components possessing thixiotropic properties, whereby the thixiotropically modified liquid will decrease in viscosity upon being mixed or otherwise mechanically agitated, then increase in viscosity upon standing unagitated. Such thixiotropic cycle is infinitely repeatable, whereby further mixing of said liquid will decrease viscosity again, and upon further standing unagitated will increase viscosity again. The term RHEOLOGY MODIFIERS as used herein are small particulates of about 1 millimeter or less in diameter, or small fibers of about 1 millimeter or less in length, or combinations thereof, which are incorporated into said polymer resin to formulate a polymer resin composite employed to form the Matrix intended to bond subject webs together. Particulates or fibers employed as rheology modifiers are sub-classified under the following sub-groups for simplicity; thixiotropic materials, and non-thixiotropic materials. THIXIOTROPIC MATERIALS are defined as silica fume and bentonite clay. NON-THIXIOTROPIC MATERIALS are defined as cyclic polybutylene terephthalate (CBT), other clays, cellulose ethers, natural gums, synthetic gums, polymers, and nano-materials.
[0098] PRODUCT IDENTIFICATION TRACERS are used to identify a product from similar products of others or counterfeit products. When properly employed, product identification tracers can be a powerful tool to screen for similar products appearing in the marketplace, and to determine false warranty claims when competing products of others similar in appearance are submitted for warranty claims. Physical particles/flakes which are visually identifiable, pH sensitive materials which produce a color change upon exposure to reagents within the activation pH range, and ultraviolet tracers which fluoresce when exposed to UV-A ultraviolet light (black light) are the most commonly used tracer types. Biometric tracers exist, but are presently very expensive. The preferred tracers for this embodiment of the present invention are ultraviolet tracers. The term PRODUCT IDENTIFICATION TRACERS as used herein are small particulates of about 1 millimeter or less in diameter, or small fibers of about 2 millimeters or less in length, or combinations thereof, which are incorporated into said polymer resin to formulate a polymer resin composite employed to form the Matrix intended to bond subject webs together. Particulates or fibers employed as product identification tracers are sub-classified under the following sub-groups for simplicity; ultraviolet materials, pH sensitive materials, and colored particles or fibers. ULTRAVIOLET MATERIALS are defined as any material which fluoresces when exposed to ultraviolet light. PH SENSITIVE MATERIALS are defined as any material which produces a color change when exposed to an acidic or alkaline reagent. COLORED PARTICLES OR FIBERS are defined as any particle or fiber which is uniquely identifiable by color, size and shape.
[0099] FILLERS can be classified as either functional fillers or non-functional fillers. Any of the modifiers described in this invention, including friction modifiers, thermal conductivity modifiers, rheology modifiers, and colors can technically be defined as functional fillers. Functional fillers must serve some useful purpose other than purely being employed to reduce raw-material-cost (RMC) by displacing volume or weight of a more expensive ingredient with an equal volume or weight of a less expensive ingredient. Non-functional fillers are employed only for the purpose of reducing RMC. For purposes of this invention, the term fillers is used in the pure sense of the word to mean non-functional fillers, while functional fillers have been classified and expanded upon otherwise. The term FILLERS as used herein are intended to refer to non-functional fillers solely used to reduce raw-material-cost (RMC) by displacing volume of a more expensive material with a less expensive material. All other groups of modifiers herein (friction modifiers, thermal conductivity modifiers, rheology modifiers, product identification tracers, and colors) are sometimes referred to as “functional fillers” because they act as fillers by consuming volume, but serve some secondary useful purpose in the product besides reducing RMC. These are small particulates of about 500 micrometers or less in diameter, or small fibers of about 1 millimeter or less in length, or combinations thereof, which are incorporated into said polymer resin to formulate a polymer resin composite employed to form the Matrix intended to bond subject webs together. Particulates employed as fillers are not sub-classified in this description, and are defined simply as mica, clay, feldspar, calcium carbonate, and ground silica.
[0100] COLORS are used in many commercial products to impart uniqueness to a specific brand of product, and in trademark law this topic falls under the topic of “trade dress”. A product of unique color which is not inherent to the material itself is unique and identifiable to the customer purchasing the product. Red, yellow, or blue colored pigments, or combinations thereof, may be employed in this invention and applied upon, or otherwise incorporated into, said fibers, said Bonding Layer, or a combination thereof to impart a unique color to a fiber composite friction product that would inherently be another color. The term COLORS as used herein are small pigment particulates of about 500 microns or less in diameter which are incorporated into said polymer resin to formulate a polymer resin composite employed to form the Matrix intended to bond subject webs together. Particulate pigments employed as colors are sub-classified in this description within the scope of the associated Provisional Patent Application, and defined under the following sub-groups for simplicity; natural pigments, and synthetic pigments. NATURAL PIGMENTS are defined as any natural pigment. SYNTHETIC PIGMENTS are defined as any synthetic pigment.
[0101] Surface Treatments
[0102] Surface treatments may be employed on fibers either before or after forming said fibers into webs, and before or after forming said webs into a unified structure, or blanket. The desired overall purpose is to facilitate good adhesion and even wetting of Bonding Layer in the areas where Bonding Layer is applied. This includes a discontinuous island matrix where the applied Bonding Layer is not intended to coat a continuous film across the entire fiber or web surfaces, and only intended to provide improved adhesion and wetting properties upon said fibers or webs at the deposited island locations. Said surface treatments may also be employed to treat the small fibers or particulates mixed with said polymer resin to formulate a polymer resin composite employed for continuous film matrix, discontinuous island matrix, or saturation of unitary structure, or blanket.
[0103] Properly selected surface treatments have the ability to clean most organic contaminants from the target surfaces by oxidation, or by ablation with ions, free radicals, and electrons. An example is fiber “sizings” often employed to aid textile processing.
[0104] Properly selected surface treatments have the ability to increase surface energy of the target surfaces by incorporating chemically reactive sites onto the surfaces, and thereby increase wetting ability of the surface.
[0105] Properly selected surface treatments also have the ability to functionalize the target surfaces by incorporating chemically reactive bonding sites onto the surfaces.
[0106] Plasma treatment, corona treatment, and chemical treatment, or combinations thereof may be employed as said surface treatment methods.
[0107] PLASMA TREATMENT is defined as an electrically charged chamber through which a stream of air or other gasses are blown onto the desired target surface to be treated.
[0108] CORONA TREATMENT is defined as an electrical discharge arc through which a stream of air or other gasses are blown onto the desired target surface to be treated.
[0109] CHEMICAL TREATMENT is defined as oxidizers such as sodium hypochlorite, hydrogen peroxide, and ozone applied to the target surface to be treated.
[0110] Plasma treatment may be conducted within a vacuum atmosphere, or at atmospheric pressure.
[0111] Gases employed for plasma or corona treatment in place of air (if any) will vary depending on composition of target surface being treated, and the type of functional groups desired to be incorporated.
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Disclosed is a composite material and process for manufacture of a composite material that are used as bearings to reduce energy losses in rotating equipment and as shoes in clutches or breaks to provide increased frictional characteristics. The new and unique composite and manufacturing processes utilizes a polymer or polymer composite layer to hold nonwoven fibrous layers together during the composite manufacturing process. Additionally the bonding layer is formulated and the nonwoven fibers are treated to increase the speed and reliability of processing. The result of this and additional improvements provides large economies over the composite products and process currently in use.
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TECHNICAL FIELD
[0001] The present invention relates to a valve element and in particular to a valve element for use for charge-pressure regulation in an exhaust-gas turbocharger.
DESCRIPTION OF THE PRIOR ART
[0002] Valve elements for exhaust-gas turbochargers are known and are described for example in DE 10 2015 008 426 A1.
[0003] Valve elements of said type are commonly referred to as wastegate valves. The general and known mode of operation of an exhaust-gas turbocharger with a wastegate valve device will be described below with reference to FIGS. 1 and 20 .
[0004] During operation of the engine under load, the wastegate valve element 1 —comprising a rotatably mounted spindle 2 , a lever 3 which is attached to one end of the spindle and which projects laterally and which has a through opening, a (valve) flap plate 4 with a shank which is attached to or integrated with the flap plate centrally on one side and which is provided for being led through the lever opening, and a disc 5 as a fastening element on a led-through shank end of the flap plate 4 —is closed by way of an actuating drive 22 and an actuating arrangement 24 . Here, the flap plate 4 is pressed against a valve seat 23 by pivoting of the valve element 1 . In this way, the entire exhaust-gas flow is conducted via an exhaust-gas-side turbine wheel 19 which is fixedly connected to a connecting shaft 20 and to an intake-side compressor wheel 21 . The exhaust-gas flow accelerates the turbine wheel 19 together with the connecting shaft 20 and the intake-side compressor wheel 21 . The required combustion air is thereby compressed by the compressor wheel 21 and supplied, at positive pressure, via the charge-air cooler to a combustion chamber, which leads to significantly improved and more effective combustion of the fuel and to a greater power output of the engine.
[0005] During partial-load or overrun operation of the engine, the air compression is required to a lesser extent, or is not required. Therefore, during this type of driving, the actuating drive 22 opens the valve 1 by way of the actuating arrangement 24 , and allows the major part of the exhaust-gas flow to escape directly, and without being diverted by the turbine wheel 19 , through the “wastegate” into the exhaust tail pipe, and the air compression is reduced or eliminated. Here, the engine backpressure is also reduced. The lower backpressure reduces the pumping work and improves fuel economy.
[0006] During operation, the problem arises that the temperature of the exhaust gas can reach temperatures of over 1,000° C. The heat that is generated here is released non-uniformly to the mechanical components involved. This can give rise to stresses and distortion in the mechanical components (housing, flap plate 4 , valve seat 23 , lever 3 etc.—cf. FIG. 20 ). In the case of a rigid arrangement of the components of flap plate 4 and lever 3 , this can lead to leaks between the valve seat 23 and the sealing surface of the valve plate 4 , because the flap plate may set down on the valve seat in a skewed manner.
[0007] In order to realize a compensation here, it is known for the connection between flap plate 4 and lever 3 to be realized with a certain radial clearance between flap plate shank and lever bore and with a certain axial clearance between lever 3 and fastening disc 5 , that is to say the flap plate shank with the flap plate wobbles in the lever bore. If the wastegate valve element 1 is opened by way of the actuating drive 22 and the actuating arrangement 24 , a major part of the exhaust gas flows at high speed in turbulent fashion over the flap plate 4 fastened with a clearance to the lever 3 , and causes said flap plate to flutter. Here, the flap plate 4 may strike the lever 3 and/or the valve seat 23 in uncontrolled fashion, and the disc 5 may strike the lever 3 . This gives rise to an undesired rattling noise, and can lead to increased wear on the individual elements.
SUMMARY OF THE INVENTION
[0008] In contrast thereto, the invention proposes a valve element having the features of claim 1 .
[0009] The invention is based on the concept of further developing a generic valve element such that a spring element is provided for generating a preload between shank and lever.
[0010] According to the invention, the spring element may be designed to impart a radial spring force action relative to the valve plate shank.
[0011] With the solution according to the invention, a disturbing fluttering of the valve flap plate that has hitherto occurred when the wastegate is open is prevented, and thus the rattling noise is eliminated. Furthermore, the wear on the individual components of a wastegate valve device is reduced by way of a valve element according to the invention.
[0012] Further refinements of the invention are described in the further subclaims.
[0013] Further advantages and refinements of the invention will emerge from the description and from the appended drawings.
[0014] It is self-evident that the features mentioned above and the features yet to be discussed below may be used not only in the respectively specified combination but also in other combinations or individually without departing from the scope of the present invention.
[0015] The invention is illustrated in the drawing in highly schematic form, and not to scale, on the basis of exemplary embodiments, and will be described in detail below with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 shows an assembled wastegate valve element with pivotable spindle, lever projecting laterally therefrom, flap plate and disc, in a plan view.
[0017] FIG. 2 shows a wastegate valve element according to the invention in a lateral sectional illustration as per the section line A-A in FIG. 1 .
[0018] FIG. 3 shows an alternative embodiment of the wastegate valve element from FIG. 2 , in a lateral sectional illustration.
[0019] FIG. 4 shows a ring-shaped spring element according to the invention with a cutout for a disc-mounted arrangement, in a plan view.
[0020] FIG. 5 shows a sectional illustration through an embodiment of the spring element according to the invention as per the section line B-B in FIG. 4 , with a first profile shape.
[0021] FIG. 6 shows a sectional illustration through a further embodiment of the spring element according to the invention as per the section line B-B in FIG. 4 , with a second profile shape.
[0022] FIG. 7 shows a sectional illustration through a further embodiment of the spring element according to the invention as per the section line B-B in FIG. 4 , with a third profile shape.
[0023] FIG. 8 shows a further embodiment of the valve element according to the invention in a lateral sectional illustration as per the section line A-A in FIG. 1 .
[0024] FIG. 9 shows a variant of the valve element according to the invention from FIG. 8 .
[0025] FIG. 10 shows a ring-shaped spring element according to the invention with a cutout for plate-mounted arrangement, in a plan view.
[0026] FIG. 11 shows a sectional illustration through an embodiment of the spring element according to the invention as per the section line C-C in FIG. 10 , with a first profile shape.
[0027] FIG. 12 shows a sectional illustration through a further embodiment of the spring element according to the invention as per the section line C-C in FIG. 10 , with a second profile shape.
[0028] FIG. 13 shows a sectional illustration through a further embodiment of the spring element according to the invention as per the section line C-C in FIG. 10 , with a third profile shape.
[0029] FIG. 14 shows an enlarged detail illustration of FIG. 3 .
[0030] FIG. 15 shows an enlarged detail illustration of FIG. 2 .
[0031] FIGS. 16 and 16 a illustrate the mode of operation according to the invention in the case of a flap plate that has set down in skewed fashion, in the case of a disc-mounted configuration.
[0032] FIG. 17 shows an enlarged detail illustration of FIG. 9 .
[0033] FIG. 18 shows an enlarged detail illustration of FIG. 8 .
[0034] FIG. 19 illustrates the mode of operation according to the invention in the case of a flap plate that has set down in skewed fashion, in the case of a plate-mounted configuration.
[0035] FIG. 20 shows, in a schematic illustration, the mode of operation of an exhaust-gas turbocharger with wastegate valve arrangement.
[0036] FIGS. 21 and 22 show enlarged detail illustrations of the embodiment of FIG. 8 , with a bevel arranged in the lever bore.
[0037] FIGS. 23 and 23 a show enlarged detail illustrations of the embodiment of FIG. 28 as a welded version.
[0038] FIGS. 24 and 24 a show enlarged detail illustrations of the embodiment of FIG. 3 , with a bevel arranged in the disc bore.
[0039] FIGS. 25 and 25 a show enlarged detail illustrations of the embodiment of FIG. 27 as a riveted version.
[0040] FIG. 26 shows a radially acting, meander-ring-shaped spring element according to the invention.
[0041] FIG. 27 shows the section A-A through the valve element according to the invention with ring-shaped spring element in a plate-mounted configuration, in a riveted variant.
[0042] FIG. 28 shows the section A-A through the valve element according to the invention with ring-shaped spring element in a disc-mounted configuration, in a welded variant.
[0043] FIG. 29 shows, in a plan view, a ring-shaped spring element with cutout with trapezoidal profile for plate-side and disc-side arrangements as per FIGS. 27 and 28 .
[0044] FIG. 30 shows a sectional illustration through the spring elements according to the invention of FIGS. 26 and 29 with a trapezoidal profile as per the section line D-D of FIG. 29 .
DETAILED DESCRIPTION
[0045] FIG. 2 shows the section A-A through the valve element 1 in the case of a riveted version 6 with a ring-shaped spring element 10 or 25 with elliptical (circular) profile 8 in a disc-mounted configuration. The shank of the flap plate for riveted fastening 4 a is led through the opening in the lever 3 a . At the plate side, the lateral surface of the lever 3 a rests or abuts flat against the elevated surface of the flap plate 4 a . It is possible to see the radial clearance between the lever bore and the flap plate shank. On the disc, at the lever bore, it is possible to see the bevel 16 in which the spring element 10 or 25 is arranged with a clearance with respect to the flap plate shank. The disc 5 is riveted so as to abut against the shoulder on the flap plate shank, wherein the spring element 10 or 25 is pushed into the bevel 16 slightly and, in the process, is preloaded. The spacing between the disc-side lever surface and lever-side disc surface is the axial clearance (gap dimension) by which the flap plate with shank and fixedly riveted-on disc 5 can move in an axial direction in the lever bore. The cross section of the spring element 10 or 25 must be larger than the axial clearance. Thus, the spring element 10 or 25 cannot emerge from its introduction region. If the flap plate 4 a is pressed onto a valve seat 23 which is skewed owing to distortion, this also gives rise to a skewed position of the flap plate with shank and disc. As a result, the spring element is pushed deeper into the bevel 16 and, in the process, is radially compressed by the oblique bevel 16 , and is placed under even greater load. The restoring force of the spring element 10 or 25 increases until the disc 5 sets down on the lever surface. The mechanical end stop is thus reached, and the spring element 10 or 25 can expand no further. Overloading of the spring element 10 or 25 is thus prevented (in this regard, see also FIG. 16 and FIG. 16 a ). If the wastegate valve device is opened, the restoring force of the spring element 10 or 25 has the effect, via the bevel 16 , that the flap plate 4 a immediately returns in an axial direction into its initial position and is held there by the preload, even if it is impinged on by a flow of the exhaust gas. Rattling is thus prevented.
[0046] FIG. 3 is a variant of FIG. 2 . FIG. 3 shows the section A-A through the valve element 1 in the case of a welded version 7 with ring-shaped spring element 10 or 25 , which has a profile 9 in the shape of a rectangle with a truncated corner, in a disc-mounted configuration. The shank of the flap plate for welded fastening 4 b is led through the opening in the lever 3 a . At the plate side, the lateral surface of the lever 3 a rests flat against the elevated surface of the flap plate 4 b . It is possible to see the radial clearance between the lever bore and the flap plate shank. On the disc, at the lever bore, it is possible to see the bevel 16 in which the spring element 10 or 25 is arranged with a clearance to the flap plate shank. The disc 5 is welded so as to abut against the shoulder on the flap plate shank, wherein the spring element 10 or 25 is pushed into the bevel 16 slightly and, in the process, is preloaded. The spacing between the disc-side lever surface and lever-side disc surface is the axial clearance (gap dimension) by which the flap plate with shank and fixedly welded-on disc 5 can move in an axial direction in the lever bore. The cross section of the spring element 10 or 25 must be larger than the axial clearance. Thus, the spring element 10 or 25 cannot emerge from its introduction region. If the flap plate 4 b is pressed onto a valve seat which is skewed owing to distortion, this also gives rise to a skewed position of the flap plate with shank and disc. As a result, the spring element is pushed deeper into the bevel 16 and, in the process, is radially compressed by the oblique bevel 16 , and is placed under even greater load. The restoring force of the spring element 10 or 25 increases until the disc 5 sets down on the lever surface. The mechanical end stop is thus reached, and the spring element 10 or 25 can expand no further. Overloading of the spring element 10 or 25 is thus prevented (in this regard, see also FIG. 16 and FIG. 16 a ). If the wastegate valve is opened, the restoring force of the spring element 10 or 25 has the effect, via the bevel 16 , that the flap plate 4 b immediately returns in an axial direction into its initial position and is held there by the preload, even if it is impinged on by a flow of the exhaust gas. Rattling is thus prevented.
[0047] FIG. 4 shows the ring-shaped spring element with a cutout for disc-mounted arrangement 10 , in a plan view. The ring is not closed, such that a spring travel is possible. The spring force acts radially.
[0048] FIG. 5 shows the section B-B through the spring element for disc-mounted arrangement 10 with a profile 9 which is rectangular with a truncated corner, FIG. 6 shows the section B-B through the spring element for disc-mounted arrangement 10 with a triangular profile 11 , and FIG. 7 shows the section B-B through the spring element for disc-mounted arrangement 10 with an elliptical (circular) profile 8 .
[0049] FIG. 8 shows the section A-A through the wastegate valve element 1 in the case of a riveted version 6 with ring-shaped spring element 15 or 25 , which has a profile 12 in the shape of a rectangle with a truncated corner, in a plate-mounted configuration. The shank of the flap plate for riveted fastening 4 c is led through the opening in the lever 3 b . At the disc side, the lateral surface of the lever 3 b rests flat against the lever-side surface of the disc 5 . It is possible to see the radial clearance between the lever bore and the flap plate shank. In the elevated region of the flap plate 4 c , a ring-shaped groove is formed in coaxially with respect to the shank, which ring-shaped groove transitions into a bevel 17 on the flap plate shank. The ring-shaped groove is the introduction region for receiving the ring-shaped spring element 15 or 25 when the latter is pushed downward by the plate-side surface of the lever 3 b . The spring element 15 or 25 is arranged on the flap plate shank without a clearance. The disc 5 is riveted so as to abut against the shoulder on the flap plate shank. Here, the spring element 15 or 25 is pushed into the bevel 17 slightly and, in the process, is preloaded. The spacing between the plate-side lever surface and the elevated ring on the flap plate 4 c is the axial clearance (gap dimension) by which the flap plate with shank 4 c and fixedly riveted-on disc 5 can move in an axial direction in the lever bore. The cross section of the spring element 15 or 25 must be larger than the axial clearance. Thus, the spring element 15 or 25 cannot emerge from its introduction region. If the flap plate 4 c is pressed onto a valve seat 23 which is skewed owing to distortion, this also gives rise to a skewed position of the flap plate with shank 4 c and disc 5 . As a result, the spring element is pushed deeper into the bevel 17 and, in the process, is radially expanded by the oblique bevel 17 , and is placed under even greater load. The restoring force of the spring element 15 or 25 increases until the lever surface sets down on the flap plate ring. The mechanical end stop is thus reached, and the spring element 15 or 25 can expand no further. Overloading of the spring element 15 or 25 is thus prevented (in this regard, see also FIG. 17 and FIG. 18 and FIG. 19 ). If the wastegate valve is opened, the restoring force of the spring element 15 or 25 has the effect, via the bevel 17 , that the flap plate 4 c immediately returns in an axial direction into its initial position and is held there by the preload, even if it is impinged on by a flow of the exhaust gas. Rattling is thus prevented.
[0050] FIG. 9 is a variant of FIG. 8 . FIG. 9 shows the section A-A through the wastegate valve element 1 in the case of a welded version 7 with ring-shaped spring element 15 or 25 , which has an elliptical or circular profile 14 , in a plate-mounted configuration. The shank of the flap plate for welded fastening 4 d is led through the opening in the lever 3 b . At the disc side, the lateral surface of the lever 3 b rests flat against the lever-side surface of the disc 5 . It is possible to see the radial clearance between the lever bore and the flap plate shank. In the elevated region of the flap plate 4 d , a ring-shaped groove is formed in coaxially with respect to the shank, which ring-shaped groove transitions into a bevel 17 on the flap plate shank. The ring-shaped groove is the introduction region for receiving the ring-shaped spring element 15 or 25 when the latter is pushed downward by the plate-side surface of the lever 3 b . The spring element 15 or 25 is arranged on the flap plate shank without a clearance. The disc 5 is welded so as to abut against the shoulder on the flap plate shank. Here, the spring element 15 or 25 is pushed onto the bevel 17 slightly and, in the process, is preloaded. The spacing between the plate-side lever surface and elevated ring on the flap plate 4 d is the axial clearance (gap dimension) by which the flap plate with shank 4 d and fixedly riveted-on disc 5 can move in an axial direction in the lever bore. The cross section of the spring element 15 or 25 must be larger than the axial clearance. Thus, the spring element 15 or 25 cannot emerge from its introduction region. If the flap plate 4 d is pressed onto a valve seat 23 which is skewed owing to distortion, this also gives rise to a skewed position of the flap plate with shank 4 d and disc 5 . As a result, the spring element is pushed deeper onto the bevel 17 and, in the process, is radially expanded by the oblique bevel 17 , and is placed under even greater load. The restoring force of the spring element 15 or 25 increases until the lever surface sets down on the flap plate ring. The mechanical end stop is thus reached, and the spring element 15 or 25 can expand no further. Overloading of the spring element 15 or 25 is thus prevented (in this regard, see also FIG. 17 and FIG. 18 and FIG. 19 ). If the wastegate valve device is opened, the restoring force of the spring element 15 or 25 has the effect, via the bevel 17 , that the flap plate 4 d immediately returns in an axial direction into its initial position and is held there by the preload, even if it is impinged on by a flow of the exhaust gas. Rattling is thus prevented.
[0051] FIG. 10 shows the ring-shaped spring element with a cutout for plate-mounted arrangement 15 , in a plan view. The ring is not closed, such that a spring travel is possible. The spring force acts radially.
[0052] FIG. 11 shows the section C-C through the spring element for disc-mounted arrangement 15 with a profile 12 which is rectangular with a truncated corner, FIG. 12 shows the section C-C through the spring element for disc-mounted arrangement 15 with a triangular profile 13 , and FIG. 13 shows the section C-C through the spring element for disc-mounted arrangement 15 with an elliptical (circular) profile 14 .
[0053] FIG. 14 shows details of FIG. 3 , and FIG. 15 shows details of FIG. 2 .
[0054] FIG. 16 and FIG. 16 a show the mode of operation of the spring element 10 or 25 in the case of a flap plate 4 b that has set down in skewed fashion, in the case of a disc-mounted configuration.
[0055] FIG. 17 shows details of FIG. 9 , and FIG. 18 shows details of FIG. 8 .
[0056] FIG. 19 shows the mode of operation of the spring element 15 or 25 in the case of a flap plate 4 c that has set down in skewed fashion, in the case of a plate-mounted configuration. Here, it can also be seen, as per Patent claim 17 , that the setting-down of the flap plate 4 c and the orientation take place before the actual exertion of load, and thus more smoothly and in a more material-preserving manner.
[0057] FIG. 20 schematically shows an exhaust-gas turbocharger 18 with wastegate valve seat 23 and wastegate valve element 1 , actuating drive 22 and actuating arrangement 24 for the wastegate valve element 1 , the exhaust-gas-side turbine wheel 19 with connecting shaft 20 , and the inlet-air-side compressor wheel 21 .
[0058] FIG. 21 and FIG. 22 correspond, in terms of mode of operation, to FIG. 8 , but here, the bevel is arranged not in a ring-shaped groove in the flap plate but rather in the lever bore.
[0059] FIG. 23 and FIG. 23 a show details of FIG. 28 as a welded version.
[0060] FIG. 24 and FIG. 24 a correspond, in terms of mode of operation, to FIG. 3 , but here, the bevel is arranged not in the lever bore but rather in the disc bore.
[0061] FIG. 25 and FIG. 25 a show details of FIG. 27 as a riveted version. FIG. 26 shows the plan view of the meander-ring-shaped, radially acting spring element 25 .
[0062] FIG. 27 shows the section A-A through the wastegate valve element 1 in the case of a riveted version 6 with a ring-shaped spring element 26 or 25 with trapezoidal profile 27 in a plate-mounted configuration. The shank of the flap plate 4 e , 4 f is led through the opening in the lever 3 c . At the disc side, the lateral surface of the lever 3 c rests flat against the lever-side surface of the disc 5 . It is possible to see the radial clearance between the lever bore and the flap plate shank. A ring-shaped groove is formed into the elevated region of the flap plate 4 e , 4 f coaxially with respect to the shank, which ring-shaped groove transitions into a bevel 28 . Opposite this, a bevel 29 is likewise formed into the plate in the lever bore. The space that exists between said two bevels 28 and 29 is the introduction region for receiving the ring-shaped spring element 26 or 25 with trapezoidal profile 27 . The spring element 26 or 25 is supported by way of its two oblique surfaces both against the bevel 28 in the flap plate 4 e , 4 f and against the bevel 29 in the lever 3 c . The disc 5 is riveted so as to abut against the shoulder on the flap plate shank. Here, the spring element 26 or 25 is pushed into the bevels 28 and 29 slightly and, in the process, is preloaded. Here, centring of the flap plate with shank 4 e , 4 f in the bore of the lever 3 c is realized. The spacing between the plate-side lever surface and the elevated ring on the flap plate 4 e , 4 f is the axial clearance (gap dimension) by which the flap plate with shank 4 e , 4 f and fixedly riveted-on disc 5 can move in an axial direction in the lever bore. The cross section of the spring element 26 or 25 must be larger than the axial clearance. Thus, the spring element 26 or 25 cannot emerge from its introduction region. If the flap plate 4 e , 4 f is pressed onto a valve seat 23 which is skewed owing to distortion, this also gives rise to a skewed position of the flap plate with shank 4 e , 4 f and disc 5 . As a result, the spring element is pushed deeper onto the bevels 28 and 29 and, in the process, is radially expanded by the oblique bevels 28 and 29 , and is placed under even greater load. The restoring force of the spring element 26 or 25 increases until the lever surface sets down on the flap plate ring. The mechanical end stop is thus reached, and the spring element 26 or 25 can expand no further. Overloading of the spring element 26 or 25 is thus prevented (in this regard, see also FIG. 25 a ). If the wastegate valve is opened, the restoring force of the spring element 26 or 25 has the effect, via the bevels 28 and 29 , that the flap plate 4 e , 4 f immediately returns in an axial direction and in a radial direction into its centred initial position and is held there by the preload, even if it is impinged on by a flow of the exhaust gas. Rattling is thus prevented.
[0063] FIG. 28 shows the section A-A through the wastegate valve element 1 in the case of a welded version 7 with ring-shaped spring element 26 or 25 , which has a trapezoidal profile 27 , in a disc-mounted configuration. The shank of the flap plate 4 a , 4 b is led through the opening in the lever 3 a . At the plate side, the lateral surface of the lever 3 a rests flat against the lever-side elevated surface of the flap plate 4 a , 4 b . It is possible to see the radial clearance between the lever bore and the flap plate shank. A bevel 30 is formed into the lever-side surface of the disc 5 a . Opposite this, a bevel 16 is likewise formed into the disc in the lever bore. The space that exists between said two bevels 30 and 16 is the introduction region for receiving the ring-shaped spring element 26 or 25 with trapezoidal profile 27 . The spring element 26 or 25 is supported by way of its two oblique surfaces both against the bevel 30 in the disc 5 a and against the bevel 16 in the lever 3 a . The disc 5 a is welded so as to abut against the shoulder on the flap plate shank. Here, the spring element 26 or 25 is pushed into the bevels 30 and 16 slightly and, in the process, is preloaded. Here, centring of the flap plate with shank 4 a , 4 b in the bore of the lever 3 a is realized. The spacing between the disc-side lever surface and the lever-side planar outer ring-shaped surface on the disc 5 a is the axial clearance (gap dimension) by which the flap plate with shank 4 a , 4 b and fixedly welded-on disc 5 a can move in an axial direction in the lever bore. The cross section of the spring element 26 or 25 must be larger than the axial clearance. Thus, the spring element 26 or 25 cannot emerge from its introduction region. If the flap plate 4 a , 4 b is pressed onto a valve seat 23 which is skewed owing to distortion, this also gives rise to a skewed position of the flap plate with shank 4 a , 4 b and disc 5 a . As a result, the spring element is pushed deeper onto the bevels 30 and 16 and, in the process, is radially expanded by the oblique bevels 30 and 16 , and is placed under even greater load. The restoring force of the spring element 26 or 25 increases until the lever surface sets down on the disc ring. The mechanical end stop is thus reached, and the spring element 26 or 25 can expand no further. Overloading of the spring element 26 or 25 is thus prevented (in this regard, see also FIG. 23 a ). If the wastegate valve is opened, the restoring force of the spring element 26 or 25 has the effect, via the bevels 30 and 16 , that the flap plate 4 a , 4 b immediately returns in an axial direction and in a radial direction into its centred initial position and is held there by the preload, even if it is impinged on by a flow of the exhaust gas. Rattling is thus prevented.
[0064] FIG. 29 shows the ring-shaped spring element with a cutout 26 with trapezoidal profile 27 for plate-mounted and disc-mounted arrangement as per FIG. 27 and FIG. 28 , in a plan view. The ring is not closed, such that a spring travel is possible. The spring force acts radially.
[0065] FIG. 30 shows the trapezoidal profile 27 of the spring elements 26 and 25 .
[0066] The use of a radially acting ring-shaped spring element between the fastening disc and the lever (disc-side variant) or between the lever and the flap plate (plate-side variant) on one or two bevels eliminates the fluttering of the flap plate by way of a certain permanent preload. For this purpose, the embodiment of the bevels and of the ring-shaped spring element is selected such that the spring element is already pushed slightly onto the bevel(s) in the axial direction towards the flap plate shank during the assembly process. Here, the spring element is placed under load in a radial direction. Owing to the support on the oblique bevel(s), it is also the case here that a restoring force acts in an axial direction, with a centring action being realized in the case of support on two oppositely situated bevels.
[0067] The spring element imparts a vibration-damping action when the wastegate valve is open, and stabilizes the flap plate in its initial position. In the closed state, the spring element permits a skewed position of the flap plate within the range of the axial and radial clearance. During the opening process, the initial position is immediately re-established by way of the restoring force of the spring element.
[0068] The restoring or holding force of the spring element required in the respective usage situation may be set through variation of the bevel angle, the spring characteristic curve, the spring geometry and the axial and radial clearance. Experts at the spring manufacturer can select the optimum material for the respective usage situation.
[0069] The design of the introduction region or installation space for the spring element and the geometry of the spring element should be selected such that the spring element can be completely received in its introduction region when the lever is pushed into a block state both at the disc side and at the plate side (mechanical end stop). In this way, the spring element cannot be over-expanded or overloaded.
[0070] The use of the application according to the invention is independent of the method used for the fastening of the disc to the flap plate bolt. The disc may be welded on, riveted on, shrink-fitted on etc.
[0071] The valve device according to the invention may be arranged at the turbine side and/or compressor side in a bypass of an exhaust-gas turbocharger.
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Valve element for an exhaust-gas turbocharger, having a spindle which has a longitudinal extent, a lever which extends from the spindle laterally in relation to the longitudinal extent of said spindle and which has a through opening, a valve flap plate, a substantially disc-shaped fastening element, and a shank which extends through the through opening and which connects the valve flap plate to the fastening element, wherein the valve flap plate and the fastening element are connected to one another by way of a shank extending through the through opening of the lever, and wherein a spring element is provided for generating a preload between shank and lever.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Non-Provisional application Ser. No. 13/635,642, filed on Mar. 17, 2011, which claims priority to International Application No. PCT/US2011/028763 filed on Mar. 17, 2011, which claims priority to U.S. Provisional Application No. 61/314,677 filed on Mar. 17, 2010, the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] Currently, reactors for producing ethylene oxide (EO) by partial oxidation of ethylene typically make use of a single conventional fixed-bed shell-tube exchanger (FB) where the catalytic reaction occurs inside the tubes. The fabrication of this type of reactor has reached engineering and transportation limitations due to weight and size factors. It is typical in a conventional design to have 8,000-14,000 tubes with up to 2″ internal diameter tubes (Dt) arranged in the shell diameter (Ds) with a Ds of 6-9 meters (M) and tube sheets approaching 1.0 ft to 2.0 ft in thickness. A reactor with an even larger Dt and Ds can theoretically be used to provide a more economically advantageous process given the continually advancing catalyst formulations that are improving average selectivity of 80% to 95% during such a reactor's life time. There is a need for a reactor configuration as an alternative platform for EO catalyst with efficiency higher than 80% that is lower in weight and provides lower pressure drop across the reactor and thus provides higher return on capital investment due to lower operating and capital cost as compared to using a conventional FB reactor.
BRIEF SUMMARY
[0003] In one embodiment, the disclosure relates to a reaction vessel for production of alkylene oxide(s) from partial oxidation of hydrocarbon using a high efficiency heterogeneous catalyst in a fixed bed enclosed within a reaction vessel shell. The reaction vessel may comprise a shell having a length and a volume that defines a catalyst bed shape having a length such that an out flow area and an in flow area over the catalyst bed length in between the out flow and in flow has an absolute ratio difference less than or equal to about 1.3 M anywhere in the reactor bed. The catalyst bed defines a process side having a selectivity greater than about 80%, and the catalyst bed has a length less than the shell length and a width that defines a volume less than the shell volume. The reaction vessel further includes a fixed bed outlet zone configured with average residence time less than or equal to about 4 seconds of the gaseous product flow from the catalyst bed over the heat exchanger to quench the undesirable side reactions involving the alkylene oxide product. The vessel also includes at least one fluid coolant enclosure heat exchanger in the vessel interior with an outside surface and an inside surface. The coolant enclosure outside surface is in contact with the catalyst bed. The coolant enclosure has an inlet and an outlet for the flow of heat transfer fluid therethrough. The coolant enclosure may further define a cooling surface area with the coolant flow cross sectional area ratio to cooling surface area much less than about 1 and where pressure in the coolant side may be higher than pressure on the process side.
[0004] In another embodiment, the disclosure relates to at least one method for producing ethylene oxide from partial oxidation of ethylene using a high efficiency ethylene oxide catalyst in a fixed bed enclosed within a shell of a reaction vessel. In one embodiment, the method may comprise introducing a sufficient amount of gaseous ethylene, oxygen, ballast gases that include, but are not limited to, methane, inert gases such as N 2 , He, Ar and any other inert gas, and at least one catalyst promoter such as, but not limited to, NH 3 , vinyl chloride, ethyl chloride, and others, into an in flow of the reaction vessel and flowing the ethylene, oxygen, ballast gas and promoters over an ethylene oxide (EO) catalyst bed that provides a selectivity to EO of greater than about 80%. The reaction vessel may comprise a shell having a length and a volume that defines a catalyst bed shape having a length such that an out flow area and an in flow area over the catalyst bed length in between the out flow and in flow has an absolute ratio difference less than or equal to about 1.3 M anywhere in the reactor bed. The method further includes circulating a heat transfer fluid within a coolant enclosure contained within the reaction vessel catalyst bed. The coolant enclosure defines a coolant side, and the coolant side may have a greater pressure than the process side. The coolant enclosure has an outside surface in contact with the catalyst bed, and has an inlet and an outlet for the circulation of heat transfer fluid therethrough. Generally, the coolant enclosure defines a cooling surface area with a coolant flow cross sectional area ratio to cooling surface area much less than about 1. The reaction vessel further includes a fixed bed outlet zone configured with an average residence time less than or equal to 4 seconds of gaseous product flow from the outlet of the catalyst bed over the heat exchanger to quench any undesirable side reactions involving the ethylene oxide product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A is a schematic representation of a reaction vessel according to at least one embodiment;
[0006] FIG. 1B is a cross sectional view of the heat transfer fluid enclosure of FIG. 1 ;
[0007] FIG. 2A is an evaluation of a catalyst-in-shell side reactor design with cross flow (XCSA) for a low selectivity catalyst with a GHSV of 5631 1/hr;
[0008] FIG. 2B is an evaluation of a catalyst-in-shell side reactor design with cross flow (XCSA) for a low selectivity catalyst with a GHSV of 7525 1/hr;
[0009] FIG. 2C is a plot of heat transfer area to catalyst volume ratio φ as function of reactor bed length for XCSA reactor designs with various coolant tube diameters and various coolant temperatures yielding different work rates for a low selectivity catalyst;
[0010] FIG. 2D is a plot of heat transfer area to catalyst volume ratio φ as function of reactor bed length for XCSA reactor designs at different GHSV values for a low selectivity catalyst;
[0011] FIG. 2E is a plot of heat transfer area to catalyst volume ratio φ as function of reactor bed length for XCSA reactor designs with various coolant tube diameters and various coolant temperatures yielding different work rate for a low selectivity catalyst;
[0012] FIG. 2F is a plot of heat transfer area to catalyst volume ratio as function of reactor bed length for XCSA reactor designs with various tube diameters and various coolant temperatures yielding different work rate for a low selectivity catalyst;
[0013] FIG. 2G is a plot of heat transfer area to catalyst volume ratio as function of reactor bed length for XCSA reactor designs with various tube diameters and various coolant temperatures yielding different work rate for a low selectivity catalyst;
[0014] FIG. 2H is a plot of NPV savings of a feasible XCSA design with coolant tube as a function of bed length, as compared to an STR case with various heat transfer area ratios to catalyst volumes (or tube ID) for a low selectivity catalyst;
[0015] FIG. 3A is an evaluation of catalyst-in-shell side reactor design with cross flow (XCSA) for a high selectivity catalyst with a GHSV of 6652 1/hr;
[0016] FIG. 3B is an evaluation of catalyst-in-shell side reactor design with cross flow (XCSA) for a high selectivity catalyst with a GHSV of 8500 1/hr;
[0017] FIG. 3C is a plot of heat transfer area to catalyst volume ratio for high selectivity catalyst as a function of reactor bed length for XCSA reactor designs with various tube diameters;
[0018] FIG. 3D is a plot of heat transfer area to catalyst volume ratio for a high selectivity catalyst as function of reactor bed length for XCSA reactor designs having different GHSV values;
[0019] FIG. 3E is a plot of the heat transfer area to catalyst volume ratio as function of reactor bed length for XCSA reactor designs with various coolant temperatures yielding different work rate for a high selectivity catalyst;
[0020] FIG. 3F is a plot of heat transfer area to catalyst volume ratio as function of reactor bed length for XCSA reactor designs with various coolant temperatures yielding different work rate for a high selectivity catalyst;
[0021] FIG. 3G is a plot of NPV savings of feasible XCSA designs with coolant tubes OD of 0.75″ as a function of bed length, as compared to an STR case with various heat transfer area ratio to catalyst volume (or tube ID) for a high selectivity catalyst;
[0022] FIG. 4 is a schematic of radial flow reactor and cone shaped catalyst bed reactor designs;
[0023] FIG. 5A is an evaluation of catalyst-in-shell side axial flow designs with flow parallel to the coolant carrier (CSA) for low selectivity catalyst as compared to an STR case;
[0024] FIG. 5B is an evaluation of catalyst-in-shell side axial flow designs with flow parallel to the coolant carrier (CSA) for low selectivity catalyst as compared to an STR case;
[0025] FIG. 6A is an evaluation of catalyst-in-shell side axial flow designs with flow parallel to the coolant carrier (CSA) for high selectivity catalyst as compared to an STR case;
[0026] FIG. 6B is an evaluation of catalyst-in-shell side axial flow designs with flow parallel to the coolant carrier (CSA) for high selectivity catalyst as compared to STR case;
[0027] FIG. 7 shows the comparison of XCSA reactor designs and conventional reactor designs performance of various ranges of catalyst bed porosity and density for low selectivity catalyst;
[0028] FIG. 8 shows the comparison of an XCSA and conventional reactor designs performance for various ranges of catalyst bed porosity and density for a high selectivity catalyst.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Turning now to the drawings wherein like numbers refer to like structures, FIG. 1A is a schematic representation of a reaction vessel 10 having a shell enclosure 12 of a length and width that defines an internal space 14 . The shell is a wall with an inner surface 16 and an outer surface 18 , separated by an insulation layer 20 . While the shell is shown schematically, those skilled in the art understand that it could be constructed in any shape desired. The shell is constructed of materials having sufficient strength to contain the internal pressures that arise as the operation of the reaction vessel as is well known in the art. The reaction vessel is further equipped with an in flow 22 for ingress of hydrocarbon or other gaseous raw materials, such as, for example ethylene, oxygen, ballast gases, and gaseous catalyst promoters, into the feed distribution device 24 and an out flow 26 for effluent gaseous products. In this regard, it is apparent to those skilled in the art that the term “ballast gases” are understood to be, but are not limited to, CO 2 , CH 4 , inert gasses such as N 2 , Helium, Argon, or any other noble gas. Similarly, catalyst promoters may be, but are not limited to, ammonia (NH 3 ), especially for high selectivity catalysts, chlorides, vinyl chloride, ethyl chloride, ethane, and any other suitable gaseous promoter. The in flow and the out flow of the shell are configured to produce an exit gas velocity of from about 5 ft/s, to about 25 ft/s, upon exiting the fixed bed reaction zone within the reactor vessel before entering an outlet pipe 31 . The gaseous in flow and out flow have an absolute ratio difference of inlet and outlet flow area over the catalyst bed length from about 0.8 meters to about 1.3 meters and more preferably from about 0.9 to about 1.2 meters. In one embodiment, the shell has an interior pressure during gaseous raw material ingress and gaseous effluent product egress of less than about 350 psig.
[0030] Between the in flow and the out flow, there is a catalyst bed 28 carried within the shell made of a high or low selectivity catalyst for the oxidation of the gaseous raw material, such as, for example ethylene, to ethylene oxide in a manner to be hereinafter described. The catalyst bed is also known as the process side of the reactor and has a length and a width and defines a volume that is less than the volume of the shell. At any point A 1 and A 2 , between the in flow and the out flow, the catalyst bed has a length L 1 such that between the out flow area and the in flow area over the catalyst bed length in between the out flow and the in flow, has an absolute ratio difference as expressed in (A 2 −A 1 )/L 1 that is less than or equal to about 1.3M. Proximal to the out flow is fixed bed outlet zone 30 to minimize residence time of the effluent product material after exiting the catalytic bed. Generally, the fixed bed outlet zone is configured with an average residence time of less than or about 4 seconds for the gaseous product flow from the outlet of the catalyst bed to a heat exchanger to quench any undesired side reaction further converting alkylene oxide product to other unwanted byproducts such as CO 2 , H 2 O, carbon, and CH 4 .
[0031] The catalyst may be selected from the group of catalysts with a lifetime selectivity higher than about 80%. Suitable catalysts may include, without limitation, a low selectivity catalyst such as SureCat® or a high selectivity catalyst such as Meteor®, both available from The Dow Chemical Company. When the catalyst bed is a low selectivity catalyst, the bed has a density in a range from about 960 kg/m 3 to about 774 kg/m 3 , and if a high selectivity catalyst is used as the catalyst bed, the bed has a density in a range from about 837 kg/m 3 to about 715 kg/m 3 .
[0032] The catalyst may be pills having a diffusion length from about 0.02 inches to about 0.07 inches, and more preferably, from about 0.025 inches to about 0.06 inches. The pill diffusion length can be determined by the ratio of the volume of a catalyst pellet to its exterior surface available for reactant penetration and diffusion. A more detailed definition and example can be found on page 476 of “Chemical Reaction Engineering”, second edition, Wiley & Sons, 1972 incorporated in its entirety by reference. If a low selectivity catalyst is used, the preferred catalyst bed should have a length great than or equal to about 9.5 M, and if a high selectivity catalyst is used as the catalyst bed, the preferred bed should have a length greater than or equal to about 8.5 M.
[0033] The reactor vessel is further equipped with a coolant fluid enclosure heat exchanger 32 having an inlet 34 and an outlet 36 for the circulation of heat transfer fluid through the vessel in a manner that may be parallel or cross wise to the direction of gaseous raw material flow through the catalyst bed. As seen in FIG. 1B , the coolant enclosure is generally designated as the coolant side of the reactor, and has an outer surface 38 in contact with the catalyst bed, and an inner surface 40 , in contact with the heat transfer fluid. The coolant enclosure defines a coolant surface area with a heat transfer fluid flow cross sectional area ratio to the coolant surface area much less than 1. Moreover, the coolant enclosure surface area ratio to catalyst bed volume is preferably less than or equal to about 187 1/M. The heat transfer fluid may be boiling water in the coolant enclosure at a pressure of up to about 750 psig to maintain temperature in the catalyst bed at a temperature up to about 270° C. In addition, the pressure in the coolant side is preferably greater than the pressure on the process side of the reaction vessel.
[0034] Generally, the catalyst bed has an oxidation catalyst of a selectivity greater than about 80%, and, as previously stated, the flow of gaseous raw material through the catalyst bed may be parallel or cross to the direction of flow of heat transfer fluids in the heat transfer fluid enclosure. Accordingly, the coolant enclosure flow may be parallel, helical, perpendicular or in any other direction to the direction of flow of the gaseous raw material through the catalyst bed.
EXAMPLES
[0035] The following examples are offered to illustrate various aspects of the present invention. Those skilled in the art understand that they are not to be construed as limiting the scope and spirit of the invention. For all Figures discussed in the Examples, “XCSA” means cross flow catalyst-in-shell reactor; “GHSV” means Gas Hourly Space Velocity, “φ” means catalyst volume ratio; “SI” means calculated sensitivity index; “ΔP” means pressure drop and “STR” means conventional reactor with catalyst bed inside the tube.
Example 1
[0036] A comparison was made between a low selectivity (LS) ethylene oxide catalyst system, such as the Surecat® family and a high selectivity (HS) ethylene oxide catalyst system, such as the Meteor® family, both available from The Dow Chemical Company, with their relevant parameters particle diameter (Dp), porosity (ε), bed density (ρ B ), beginning of life (BOL) selectivity and typical end of life (EOL) selectivity. Table 1 lists some typical parameters for the low selectivity catalysts and the high selectivity catalysts.
[0000]
TABLE 1
Parameters for low and high selectivity catalysts
Selectivity
Selectivity
Case
Dp
ε
ρ B
(BOL)
(EOL)
Low Selectivity
5.32
0.44
840
84
80
High Selectivity
6.84
0.44
776
92
88
Example 2
[0037] FIG. 2A is an evaluation of a catalyst-in-shell side reactor design with cross flow (XCSA) for low selectivity catalyst with GHSV of 5631 1/hr. A comparison case is shown with a 2″ tube OD (1.83″ID) conventional shell and tube reactor with catalyst-in-tube (STR) design. For low selectivity (LS) catalysts with range of 80 to 86% such as disclosed in Example 1 above, a catalyst-in-shell with cross flow (XCSA) design with 0.75″ coolant tube with GHSV of 5631 1/hr will show advantages over the conventional shell and tube reactor with catalyst-in-tube (STR) design with 2″ tube OD (with 1.83″ ID). The STR case tube ID is such that the heat transfer area over catalyst volume ratio (φ) is 86 1/M. In this case, the XCSA design will show improved stability as shown by the larger calculated sensitivity index (SI), lower weight and lower pressure drop (ΔP) and even lower φ with XCSA reactor bed length between 6.7 and 11.7 M as shown in FIG. 2A . It is also apparent that the ΔP decreases with a lower bed length while in contrast the reactor weight increases with lower bed length.
[0038] FIG. 2B is an evaluation of catalyst-in-shell side reactor design with cross flow (XCSA) for low selectivity catalyst with GHSV of 7525 1/hr. A comparison case is shown with 2″ tube OD (1.83″ID) conventional shell and tube reactor with catalyst-in-tube (STR) design. The reactor of FIG. 2B will show a similar improvement as the reactor of FIG. 2A by using an XCSA concept with a GHSV of 7531 1/hr. Table 2 shows the detailed calculation results from LS catalyst and it also shows that similar improvement may be expected to be achieved in XCSA designs over STR designs using 2″ OD tubes (φ=86 1/M and 1.83″ID) by using different coolant tubes OD while keeping the catalyst bed volume and other operating conditions (coolant temperature, GHSV, production rate, inlet pressure, inlet gas temperature) similar to STR cases and with SI, EO outlet concentration, and selectivity similar to or better than those in STR cases. In addition, Table 2 also shows that significant improvement in the φ (and thus reactor weight) may be obtainable at various coolant tube OD (e.g. XCSA 2, 5 and 8) while still providing lower ΔPs than that of STR cases. Note also that ΔP can be much lower than that in STR cases for various coolant tubes OD while still maintaining lower weight ratio (e.g. case XCSA 3, 6, and 9).
[0000]
TABLE 2
Evaluation of catalyst-in-shell side reactor design with cross flow (XCSA) and comparison
with conventional fixed bed reactor for lower selectivity catalyst for GHSV of 5631 1/hr.
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
Case
STR
1
2
3
4
5
6
7
8
9
φ (1/m)
85.96
81
72.0
87.2
78.2
68.7
86
75.6
69
86
coolant
N/A
0.75
0.75
0.75
1
1
1
1.25
1.25
1.25
tube OD
(in)
ΔP (psig)
57.62
17.76
39.71
10.54
22.7
49.8
11.57
28
49.7
12.4
Weight
1
0.69
0.62
0.75
0.69
0.61
0.76
0.68
0.62
0.76
ratio
Ds ratio
1
0.99
0.86
1.09
0.99
0.86
1.13
0.99
0.89
1.16
L ratio
1
0.69
0.89
0.58
0.75
0.96
0.6
0.85
0.95
0.61
[0039] FIG. 2C is a plot showing the prediction of heat transfer area to catalyst volume ratio φ as a function of reactor bed length for XCSA reactor design with various coolant tube diameters and various coolant temperatures yielding different work rates (work rate is indicated in legend in lbs/ft 3 -hr) for low selectivity catalyst. The ΔP, 1/SI and weight ratio with respect to STR cases (STR with 2″ OD and D ti =1.83″) are also plotted as a function of bed length. FIG. 2C also shows the prediction that the XCSA design is advantageous over STR designs with φ STR =86 1/M for different coolant temperatures and hence different production rates. More importantly, FIG. 2C also shows the prediction that the φ of XCSA design concept is always lower than or equal to φ STR of 86 1/M when the catalyst bed length is equal to or larger than 6.5 M. In addition, this is also predicted to be true for all coolant tubes OD of 0.6″ to 1.5″ and at various coolant temperatures. Note that FIG. 2C also demonstrates that the XCSA design can provide lower weight, higher stability, and lower ΔP with bed length up to about an 11 M bed than that of the STR design.
[0040] FIG. 2D is plot showing prediction of heat transfer area to catalyst volume ratio φ as a function of reactor bed length for XCSA reactor design at different GHSV values for a low selectivity catalyst. The ΔP, 1/SI and weight ratio with STR cases (STR with 2″ OD and D ti =1.83″) are also plotted as a function of bed length. FIG. 2D illustrates the predicted advantage of an XCSA design with lower φ for various GHSV values as compared to the STR case design with φ STR =86 1/M. As shown above in reference to Table 2, both the predicted reactor ΔP and stability are also advantageous over an STR design of up to 11 M bed length.
[0041] FIG. 2E is a plot showing a prediction of heat transfer area to catalyst volume ratio φ as a function of reactor bed length for XCSA reactor design with various coolant tube diameters and various coolant temperatures yielding different work rate (work rate is indicated in legend in lbs/ft 3 -hr) for a low selectivity catalyst. The predicted ΔP, 1/SI and weight ratio with an STR case (conventional reactor with D ti =0.84″) are also plotted as a function of bed length. As is the case with FIGS. 2A through 2D , FIG. 2E demonstrates the predicted advantages of an XCSA design concept with lower φ as compared to the STR design with tube OD of 0.84″ and φ STR =186.4 1/M, at different coolant temperature and XCSA design coolant tube with OD of 0.75″ and 1.5′ with bed length in the range of 6.0 M to 12 M. This also illustrates that the XCSA design of FIG. 2E is expected to show better expected stability, requires lower expected reactor weight and ΔP at the same operating conditions as STR with tube OD of 0.84″ in the range of 6.5M to 11M bed length.
[0042] FIG. 2F is a plot showing a prediction of heat transfer area to catalyst volume ratio as a function of reactor bed length for XCSA reactor design with various tube diameters and various coolant temperatures yielding different work rate (work rate is indicated in legend in lbs/ft 3 -hr) for a low selectivity catalyst. The expected ΔP, 1/SI and weight ratio with STR case (conventional reactor with tube ID of 1.5″) are also plotted as a function of bed length. A similar trend to that indicated in FIGS. 2A through E is illustrated in FIG. 2F for the XCSA design as compared to STR design case with tube ID of 1.5″ and φ STR =105.0 1/M, at different XCSA coolant tube ODs and coolant temperatures. FIG. 2F also depicts the expected XCSA advantageous bed length range of 5.8 M to 12.0 M.
[0043] FIG. 2G is a plot showing a prediction of heat transfer area to catalyst volume ratio as a function of reactor bed length for an XCSA reactor design with various tube diameters and various coolant temperatures yielding different work rate (work rate is indicated in legend in lbs/ft 3 -hr) for a low selectivity catalyst. The expected ΔP, 1/SI and weight ratio with STR case (conventional reactor with tube ID of 2.17″) are also plotted as a function of bed length. A similar trend as seen in FIGS. 2A through 2F is also illustrated in FIG. 2G for the XCSA design as compared to the STR case design with tube ID of 2.17″ or φ STR =72.6 1/M, at different coolant tube OD and coolant temperature. FIG. 2G also depicts the expected XCSA advantageous bed length range of 7.5 M to 11.5 M.
[0044] Finally, an expected overall net present value (NPV) improvement over the STR design of all the advantageous XCSA designs with various φ STR values is plotted against the bed length in FIG. 2H . The expected overall NPV improvement expected from savings in operating cost (Operating ΔP) and capital cost (approximately proportional to reactor weight) as compared to STR case with tube OD of 2″, shows a maximum along the bed length range. For lower reactor bed lengths, NPV savings from operating costs are expected to increase, due to lower pressure drop across the reactor, and higher bed length savings from capital investment are expected to be higher due to lower reactor weight. This gives rise to the highest expected NPV savings at an intermediate length range from 8 to 9.5 M. More importantly FIG. 2H also shows that the expected NPV improvement of the XCSA design may begin to be realized for the case with φ STR of 186.4 1/M or tube OD of 0.84″ in the STR design.
Example 3
[0045] FIG. 3A is a predicted evaluation of a catalyst-in-shell side reactor design with cross flow (XCSA) for a high selectivity catalyst with a GHSV of 6652 1/hr. The STR case is using a 2″ tube OD (1.83″ID) for a conventional shell and tube reactor with catalyst-in-tube design. As depicted therein, for a high selectivity (HS) catalyst with range of 86 to 95%, the catalyst on the shell side with cross flow (XCSA) design with 0.75″ coolant tube with GHSV 6652 1/hr is expected to show advantages over the conventional shell and tube reactor with catalyst-in-tube (STR) design with 2″ tube OD (1.83″ID). The STR case has the same φ=86 1/M, as seen in Example 2. FIG. 3A depicts that the expected XCSA design requires lower φ than the STR design and also shows predicted improved stability, lower reactor weight and lower pressure drop (ΔP) with reactor bed length between 6M and 9M.
[0046] Similar improvements are also expected for a case with different GHSV as shown in FIG. 3B . FIG. 3B is an evaluation of a predicted catalyst-in-shell side reactor design with cross flow (XCSA) for a high selectivity (HS) catalyst (Meteor) with a GHSV of 8500 1/hr. The STR case is with a 2″ tube OD (1.83″ID) conventional shell and tube reactor with catalyst-in-tube design. Table 3 shows the detailed calculations expected results for HS catalyst and also shows that similar improvement can be expected to be achieved in an XCSA design over an STR design by using different coolant tube OD's while keeping catalyst volume and other operating conditions (coolant Temperature, GHSV, production rate, inlet pressure, inlet gas temperature) similar to the STR case. Table 3 also shows that significant improvement in the φ (thus reactor weight) is expected to be obtained at various coolant tube OD's (e.g. XCSA 2, 5 and 8) while still providing similar or lower ΔP than that of the STR case. Note that ΔP is expected to be much lower than that in STR case for various coolant tube OD while still maintaining lower weight ratio (e.g. case XCSA 1, 2, 6 and 7).
[0000]
TABLE 3
Catalyst-in-shell side reactor designs with cross flow (XCSA) and comparison with conventional
fixed bed reactor for high selectivity catalyst with GHSV of 6652 1/hr.
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
XCSA-
Case
STR
1
2
3
4
5
6
7
8
9
Φ, Heat
86
76
70
86.0
75
71
72.5
75
69
76
transfer/cat
vol (1/M)
coolant tube
N/A
0.75
0.75
0.75
1
1
1
1.25
1.25
1.25
OD (in)
ΔP (psig)
37.7
29.9
41.5
15
14.52
33.45
21.48
18.43
37.28
12.59
Weight ratio
1
0.68
0.63
0.77
0.71
0.66
0.68
0.72
0.65
0.74
Ds ratio
1
0.88
0.83
1.00
1
0.87
0.93
1.00
0.88
1.07
L ratio
1
0.93
1.03
0.74
0.78
1.02
0.89
0.84
1.05
0.74
[0047] FIG. 3C is a plot showing a prediction of heat transfer area to catalyst volume ratio for high selectivity catalyst as a function of reactor bed length for an XCSA reactor design with various tubes. Work rate is indicated in legend in lbs/ft 3 -hr. The expected ΔP, 1/SI and weight ratio with STR case tube OD's of 2″ (ID of 1.83″) are also plotted as a function of bed length. FIG. 3C shows that various XCSA designs are expected to be advantageous over an STR design with φ STR =86 1/M for different coolant temperatures and hence different production rates. FIG. 3C also shows that the φ of an XCSA design concept is always lower than or equal to φ STR of 86 1/M when bed length is equal to or larger than 6.2 M and this is valid for all coolant tubes OD of 0.75″ to 1.5″ and at various coolant temperatures. FIG. 3C also demonstrates that an XCSA design concept is expected to have lower weight, stability, and ΔP up to a bed length of about 9.5 M as compared to an STR design. As shown above, both the predicted reactor ΔP and stability are also advantageous over an STR design up to 9.5 M bed length.
[0048] FIG. 3D is a plot showing a prediction of heat transfer area to catalyst volume ratio as function of reactor bed length for an XCSA reactor design at different GHSV values. The expected ΔP, 1/SI and weight ratios with the STR case (conventional reactor with D ti =1.83″) are also plotted as a function of bed length for a high selectivity catalyst, such as Meteor. FIG. 3D illustrates the expected advantage of an XCSA design with lower φ for various GHSV values as compared to an STR case design with φ STR =86 1/M. As shown above, both the expected reactor ΔP and stability are also advantageous over an STR design up to 9.5 M bed length.
[0049] FIG. 3E is a plot showing a prediction of heat transfer area to catalyst volume ratio as function of reactor bed length for an XCSA reactor design with various coolant temperatures yielding different work rate for a high selectivity catalyst. Work rate is indicated in legend in lbs/ft 3 -hr. The expected ΔP, 1/SI and weight ratio with an STR case (conventional reactor with tube ID of 0.84″) are also plotted as a function of bed length. FIG. 3E is similar to FIGS. 3A through 3D , and demonstrates the predicted advantages of an XCSA design concept with lower φ as compared to an STR case design with tube OD of 0.84″ and φ STR =186.4 1/M, at different coolant temperature and design coolant tubes with OD of 0.75″ with bed length in the range of 7.5 M to 9.0 M. FIG. 3E also illustrates that the XCSA design shows better expected stability, requires lower reactor weight and ΔP at the same operating conditions as an STR with tube OD of 0.84″ in the range of 7.5 to 9.8 M bed length.
[0050] FIG. 3F is a plot showing a prediction of heat transfer area to catalyst volume ratio as a function of reactor bed length for an XCSA reactor design with various coolant temperatures yielding different work rates for a high selectivity catalyst. Work rate is indicated in legend in lbs/ft 3 -hr. The expected ΔP, 1/SI and weight ratio with the STR case (conventional reactor with tube ID of 1.5″) are also plotted as a function of bed length. FIG. 3F is similar to FIGS. 3A through 3E , and sets forth the predicted advantages of an XCSA design as compared to an STR design case with tube ID of 1.5″ and φ STR =105 1/M, at different XCSA coolant temperatures. FIG. 3F also depicts the XCSA is expected to have an advantageous bed length range of 7.8 M to 9.0 M.
[0051] FIG. 3G is a plot of predicted NPV savings of a feasible XCSA design with coolant tube OD of 0.75″ as a function of bed length, as compared to an STR case with various heat transfer area ratio to catalyst volume (or tube ID) for a high selectivity catalyst. The expected overall net present value (NPV) improvement over the STR design of all the advantageous XCSA designs with various φ STR values are plotted against the bed length in FIG. 3G for the high selectivity catalyst system. The expected overall NPV improvement coming from savings in operating cost (proportional to the operating ΔP) and capital cost (proportional to the reactor weight) as compared to base case STR with tube OD of 2″, shows a maximum along the bed length range. For lower reactor bed length, expected NPV savings from operating costs are higher as seen in FIG. 3G , and for higher bed length, predicted savings from capital investments are higher due to lower reactor weight, as seen in FIG. 3F . This gives rise to a highest expected NPV at an intermediate length range from 7.0 to 8.5 m. More importantly FIG. 3G also shows that the NPV improvement of the XCSA design may be expected to be realized for the case with φ STR of 186.4 1/M or tube OD of 0.84″ in the STR design.
Example 4
[0052] This example illustrates the predicted impact of a reactor catalyst bed with varying areas in the direction of process flow. The ratio of the absolute difference between outlet and inlet area over the catalyst bed length A L of less than 1.3 M indicates where the reactor could be operated with sufficient stability. For a tubular type of reactor this can be represented with a truncated cone shape catalyst bed with an angle of 9° as shown in FIG. 4 . This 9° angle represents the predicted expansion in the shell and tubes such that heat transfer area to catalyst volume is maintained at 67 (1/M). When A L is larger than 1.3 M as is the case in the radial flow reactor as shown in Table 5, the reaction is predicted to run away since the flow rate would decrease with bed length and reduce the heat transfer rate.
[0000]
TABLE 5
Design variables of radial flow design and variable area design at
constant catalyst volume with coolant tube OD of 0.75″ and φ = 67 1/M.
Varying area
Radial Flow
axial flow
Radial Flow
Case
Design
design (9°)
Design
Bed length, L (M)
5.5
6.4
4.5
D i for Radial design (M)
1
N/A
2
A L (M)
19.2
1.3
18.9
Example 5
[0053] FIG. 5A shows the predicted feasible catalyst-in-shell design with reactant gas flowing parallel (CSA) to the heat transfer surface area with LS catalyst (e.g. Surecat® family as seen Example 1) with a coolant tube OD of 0.75″. This case is compared with a 2″ tube OD (1.83″ID) conventional shell and tube reactor with catalyst-in-tube (STR) design. The heat transfer area to catalyst volume required for the CSA design is expected to be the same as the STR case (φ=86 1/M). The cross flow configuration (XCSA) is expected to provide better heat transfer than the CSA design with lower φ values (lowest φ value required for XCSA design is 22% lower than the STR case). The heat transfer coefficient for the XCSA design with cross flow configuration is predicted to be almost twice that of the CSA design. The wider feasible catalyst-in-shell design window for the XCSA design is expected to be achieved with a bed length in the range of 6.7-11 M as compared to the CSA design with a bed length range of 9-11 M. This may be seen in a comparison of FIG. 2A and FIG. 5A . The expected minimum ΔP for the XCSA design is 80% lower than the STR case, as compared to expected minimum ΔP for the CSA design, which is only 50% lower than the STR case. The predicted minimum reactor weight for the feasible XCSA design is 42% lower than the STR case as compared to the predicted minimum reactor weight for CSA design, which is 31% lower than the STR case. Similarly, FIG. 5B also shows the expected advantages of the CSA design with coolant tube OD of 1″ as compared to the STR case. The overall expected performance of the XCSA design is better than the CSA design with lower φ values, lower ΔP, lower reactor weight and better reactor stability.
Example 6
[0054] FIG. 6A shows the predicted feasible catalyst-in-shell design with reactant gas flowing parallel (CSA) to the heat transfer surface area with HS catalyst (e.g. Meteor family as seen in example 1) with a coolant tube OD of 0.75″. The heat transfer area to catalyst volume required for the CSA design is the same as the STR case (φ=86 1/M). The cross flow configuration of the predicted XCSA provides better heat transfer than a CSA design with lower φ values. Note that the lowest expected φ value required for the XCSA design is 20% lower than the STR case. The heat transfer coefficient for an XCSA design with cross flow configuration is predicted to be almost twice that of a CSA design. The wider feasible catalyst-in-shell design window for an XCSA design may be achieved with a bed length in the range of 6.0-9 M as compared to a CSA design with a bed length range of 7.6-8.8 M. This can be seen in a comparison of FIG. 3A and FIG. 6A . The expected minimum ΔP for an XCSA design is 50% lower than the STR case, as compared to the predicted minimum ΔP for the CSA design, which is only 37% lower than the STR case. The expected minimum reactor weight for the feasible XCSA design is 37% lower than the STR case as compared to predicted minimum reactor weight for CSA design, which is 27% lower than the STR case. The STR case depicted is with a 2″ tube OD (1.83″ID) conventional shell and tube reactor with catalyst-in-tube (STR) design.
[0055] FIG. 6B is an evaluation of a predicted catalyst-in-shell side axial flow design with flow parallel to the coolant carrier (CSA) for high selectivity catalyst as compared to the STR case. As is the case with FIG. 6A , FIG. 6B shows the expected advantages of a CSA design with coolant tube OD of 1″ as compared to the STR case. The overall performance of the XCSA design is predicted to be better than the CSA design with lower φ values, lower ΔP, lower reactor weight and better reactor stability.
Example 7
[0056] The expected porosity and catalyst bed density effect on low selectivity EO catalyst system with XCSA design is shown in FIG. 7 . The porosity (ε) is varied from 0.4 to 0.48 as compared to typical value of 0.44. FIG. 7 shows that for all the porosity ranges and the corresponding catalyst bed density ranges, the XCSA design is expected to always perform better than the corresponding STR case with lower ΔP, lower reactor weight, and better stability. The predicted preferred range of catalyst bed porosity is within 0.43-0.45.
Example 8
[0057] The predicted effect of porosity and catalyst bed density on a high selectivity EO catalyst system with an XCSA design is shown in FIG. 8 . The porosity (ε) is varied from 0.4 to 0.48 as compared to a typical value of 0.435. FIG. 8 shows that for all the porosity ranges and the corresponding catalyst bed density ranges, the XCSA design is always predicted to perform better than the conventional STR case with lower ΔP, lower reactor weight, and better reactor stability. The expected preferred range of catalyst bed porosity is within 0.42-0.44.
[0058] Those skilled in the art recognize that the words used in this specification are words of description and not words of limitation. Many variations and modifications will be apparent to those skilled in the art upon a reading of this application without departing from the scope and sprit of the invention as set forth in the appended claims.
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At least one method to efficiently produce alkylene oxide from partial oxidation of hydrocarbons using a high efficiency heterogeneous catalyst in a fixed bed enclosed within a reaction vessel, and a reaction vessel constructed to facilitate the same.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a drum scanner with a loading magazine for copy cylinders.
The published European Patent Document EP 0 270 011 B1 describes a drum scanner wherein a number of copy cylinders with longitudinal axes disposed horizontally are placed in a loading magazine formed as an uprightly standing rotary disk. Each of the copy cylinders, respectively, is disposed in a scanning position wherein it is rotated at one end about the longitudinal axis thereof while a carriage bearing a scanning element is moved parallel to the axis of the copy cylinder. This drum scanner is able to scan a number of copy cylinders one after another automatically. In a further embodiment, a horizontally movable loading magazine from which, respectively, a copy cylinder can be removed by a robot arm and, after being rotated about a number of axes, can be set onto a holding and rotating device.
In the conventional drum scanner with a loading magazine, it is not possible for the operator of the drum scanner to place copy cylinders into the loading magazine or to remove them therefrom during the continuous scanning operation, because the effects of shocks on the loading magazine are transmitted to the copy cylinder then being scanned or to the sensing element, which can have a detrimental influence upon the scan result. In the heretofore known embodiment with a robot arm, although changing a magazine during continuous operation would be conceivable if the subassemblies are sufficiently stable and solid, the construction and the control of the robot arm are relatively expensive and complicated.
SUMMARY OF THE INVENTION
It is accordingly an object of the invention to provide a drum scanner and loading magazine combination which avoids the foregoing disadvantages of heretofore known constructions of this type.
With the foregoing and other objects in view, there is provided, in accordance with the invention, in combination, a drum scanner and a loading magazine, the drum scanner comprising a holding and rotating device equipped for holding an interchangeable copy cylinder firmly from below in an at least approximately upright position and for rotating it about a longitudinal axis thereof for scanning, and the loading magazine being constructed for containing a plurality n of magazine spaces equipped for holding copy cylinders in the same orientation and at the same height as on the holding and rotating device of the drum scanner, the n magazine spaces and the holding and rotating device being arranged at regular intervals around a cylinder transport carousel having n+1 outriggers extending in a star-shaped manner relative to the n magazine spaces and the holding and rotating device, and being equipped for lifting, together with the aid of the outriggers, copy cylinders located in the n magazine spaces and on the holding and rotating device, respectively, for moving them in a circle and for setting them down again at a desired location, the drum scanner and the loading magazine being separable subassemblies connected mechanically to one another by connecting elements with vibration-damping properties, and being, respectively, provided with at least one foot for bearing the weight virtually of the respective subassembly.
In accordance with another feature of the invention, the cylinder transport carousel is fixed to the drum scanner and is not in contact with the loading magazine in any position.
In accordance with a further feature of the invention, each magazine space includes an annular antenna having an axis coinciding with the longitudinal axis of a copy cylinder located in the magazine space, each of the copy cylinders having a transponder on the underside thereof wherein an electronic file name is stored which can be read out and rewritten via the antenna.
In accordance with an added feature of the invention, each of the copy cylinders bears a barcode as an optical file name, and the drum scanner includes a barcode reader equipped for reading the barcode from a respective copy cylinder rotating on the holding and rotating device, the electronic file name of the respective copy cylinders being normally identical with the optical file name thereof.
In accordance with a concomitant feature of the invention, the drum scanner and the loading magazine are equipped for accommodating and for processing copy cylinders with different diameters.
Thus, a drum scanner according to the invention includes a holding and rotating device which is equipped for holding an interchangeable copy cylinder firmly from below in an at least approximately upright position and for rotating it about its longitudinal axis for scanning. A loading magazine for the drum scanner contains a number n of magazine spaces which are equipped to hold copy cylinders in the same orientation and at the same height as on the holding and rotating device of the drum scanner. The n magazine spaces and the holding and rotating device are arranged at regular intervals around a cylinder transport carousel which has n+1 outriggers, which extend in a star shape in relation to the n magazine spaces and the holding and rotating device. The cylinder transport carousel is equipped for lifting copy cylinders, which are located in the n magazine spaces of the holding and rotating device, together with the aid of the outriggers, to move them in a circle and to set them down again at a desired location. The drum scanner and the loading magazine are subassemblies which can be separated from one another, are connected mechanically to one another by connecting elements with vibration-damping properties, and each of which is provided with one or more feet which essentially bear the weight of the respective subassembly.
The invention makes it possible for the operator of the drum scanner, during continuous scanning operation, to place copy cylinders into the loading magazine or to remove them therefrom. As noted hereinbefore, in a conventional drum scanner with a loading magazine, this is not possible, because the effects of shocks on the loading magazine are transmitted to the copy cylinder then being scanned or to the sensing element, which can have a detrimental influence upon the scan result. In the known embodiment with a robot arm, although changing a magazine during continuous operation would be conceivable if the subassemblies are sufficiently stable and solid, the construction and the control of the robot arm are relatively expensive and complicated.
Decoupling the vibrations of drum scanner and loading magazine according to the invention permits the changing of copy cylinders during production or continuous operation without requiring that the subassemblies be particularly stable or solid. The possibility of changing copy cylinders during production or continuous operation means that the operator can adapt the flow of work to the then current requirements, because he or she can change the copy cylinders at any time without having to wait until the drum scanner is at a standstill or is switched off. It is therefore possible for the working sequence to be configured very flexibly.
The vibration-damping connecting elements hold the two subassemblies at least approximately in the correct position in relation to one another. Shocks when changing copy cylinders in the loading magazine are not transmitted to the drum scanner, but are absorbed by the base upon which the loading magazine is supported. A cylinder or roller change is thereby possible at any time, at least if it is performed carefully. A careful roller change is made easier by the fact that the copy cylinders stand at least approximately upright and can be set in place from above.
The at least approximately upright position of the copy cylinders, both in the loading magazine and in the drum scanner, additionally makes it possible to use a cylinder transport carousel, which represents a considerably simpler transport device than the robot arm disclosed by the prior art. In order that the cylinder transport carousel may be able to fulfill its function without any risk that it will transmit shaking of the loading magazine to the drum scanner, it can be fixed either to the drum scanner or to the loading magazine, so as not to come into contact with the respective other subassembly in any position. In a preferred embodiment, the cylinder transport carousel is fixed to the drum scanner, specifically in the vicinity of a casting which forms a base for the holding and rotating device.
Because of the vibration-damping connecting elements, the drum scanner and the loading magazine can move a little relative to one another. The accuracy required for inserting a copy cylinder correctly into the drum scanner can, however, easily be achieved by guides and interrogation elements. Suitable as guides are, for example, tapered, i.e., self-centering, cylinder holders in the drum scanner or loading magazine, and suitable as interrogation elements are, for example, light barriers or sensors for registering the position of the cylinder transport carousel.
Although the vibration-damping connecting elements do not prevent the shocks occurring during a change of the copy cylinder in the drum scanner from getting into the drum scanner as well, this does not lead to any disruption, because changing the copy cylinder in the drum scanner can necessarily be performed only in the scanning pauses.
The construction as separate subassemblies offers the additional benefit that existing drum scanners can be retrofitted with the loading magazine without difficulty, and that the loading magazine can easily be disassembled again if it is not needed.
In conjunction with the possibility of being able to change copy cylinders at any time, it is moreover advantageous for each magazine space to contain an annular antenna having an axis which coincides with the longitudinal axis of a copy cylinder located in the magazine space, and each copy cylinder has a transponder, on the underside thereof, wherein an electronic file name is stored which can be read out and rewritten via the antenna.
The antenna at each magazine space makes it possible to identify all the copy cylinders stored in the loading magazine at any time. As a result, it is also possible, without difficulty, to remove any desired copy cylinder from the loading magazine at any time and to reinsert it. If, for example, a copy cylinder is removed from the loading magazine after a prescan (coarse scanning), this can be detected by the scanner control system, and a fine scan (fine scanning) is not performed until the scanner control system detects that the corresponding copy cylinder is again located in the loading magazine. In this regard, it does not matter at which magazine space the temporarily removed copy cylinder is replaced.
If any copy cylinder which has newly arrived is to be scanned first, it can be placed on any free magazine space and, if the loading magazine is full, it can be interchanged with any copy cylinder which has not yet been scanned or has been scanned only roughly. In order to scan the new copy cylinder, the current operating sequence is simply interrupted at a suitable location, and the new copy cylinder is transported into the rotating and holding device with the aid of the cylinder transport carousel, is scanned there and then conveyed back to a free magazine space. After that, the original operating sequence can immediately be resumed automatically. If the operator forgets to replace the temporarily removed copy cylinder in any magazine space, the scanner control system can draw attention thereto with a warning signal.
Copy cylinders for drum scanners normally have a hollow shaft, so that an identification device, like the transponder, cannot be fitted centrally. The annular antennas make it possible to read the code from such copy cylinders in any position in relation to a magazine space. As a result, it is neither necessary for the operator to pay attention to a specific angular position when inserting an copy cylinder, nor is it necessary to move the copy cylinder in any way in order to read the file name, as is necessary in the prior art.
The use of a freely programmable transponder makes it possible to retrofit existing drum scanner systems without a loading magazine, wherein each copy cylinder bears a barcode as an optical file name which is read optically in the rotating and holding device of the scanner, with a loading magazine without difficulty. The optical file name can remain the governing file name, even after the retrofit.
If the scanner control system determines, in the case of a copy cylinder located in the rotating and holding device, that the electronic file name thereof, which has previously been read in the loading magazine, does not agree with the optical file name, the copy cylinder is then transported to a free magazine space with the aid of the cylinder transport carousel, and is there provided with the appropriate electronic file name before it is processed further.
The transponders used, respectively, have a chip which stores the electronic file name and, preferably, further data such as features of the copy cylinder and/or comments. The electronic file name and, if necessary or desirable, further data can be read or rewritten via high-frequency signals from the antenna. The chip does not have its own power supply, but is supplied with power via the high-frequency energy which the antenna radiates.
The arrangement of the transponder according to the invention makes it possible to equip the holding and rotating device and the loading magazine in such a way that copy cylinders with different diameters can be processed.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a drum scanner with loading magazine, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective disassembled view of a drum scanner and a loading magazine therefor, according to the invention;
FIG. 2 is a vertical sectional view of the drum scanner of FIG. 1, with a copy cylinder provided therein;
FIG. 3 is a vertical sectional view of the loading magazine of FIG. 1, with a copy cylinder provided therein;
FIG. 4 is a vertical sectional view of the drum scanner and the loading magazine in assembled state;
FIG. 5 is an enlarged fragmentary vertical sectional view of the loading magazine taken in the region of a magazine space wherein a copy cylinder is to be disposed; and
FIGS. 6 a and 6 b are timing diagrams for explaining examples of operating sequences on a drum scanner, FIG. 6 a showing an operating sequence without a loading magazine and FIG. 6 b showing a corresponding operating sequence with a loading magazine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and, first, particularly to FIG. 1 thereof, there is shown therein, in a perspective view, a drum scanner 2 and a loading magazine 4 , which are disassembled and separated from one another.
The drum scanner 2 shown in detail in FIG. 2 has an elongated upright frame 6 with four feet 8 made of rubber or other vibration-damping material. At the front and approximately at the mid-height of the frame 6 , there is a casting 10 , wherein a spindle 12 having a vertical axis of rotation is rotatably mounted. The spindle 12 can be rotated by a non-illustrated electric motor and, at the upper end thereof, bears a cone 14 for forming a holding and rotating device for copy cylinders 16 .
Each copy cylinder 16 has a hollow cylinder body 18 formed of transparent material which, at one end, is held in a metal flange 20 . The flange 20 has a tubular extension 22 which extends axially with respect to the hollow cylinder 18 . Formed in the extension 22 is an internal taper 50 (note FIG. 5 ), which fits onto the cone 14 on the spindle 12 .
A copy cylinder 16 placed on the cone 14 of the spindle 12 assumes the upright position shown in FIG. 2 . During operation, it is rotated about its axis by the spindle 12 , while a non-illustrated optical sensing element, which is directed onto the outside of the copy cylinder 16 , is moved parallel to the axis of the copy cylinder 16 , in order to scan the copy cylinder 16 along circular or helical lines. The originals, which are adhesively bonded to the outside of the transparent hollow cylinder 18 , can either be illuminated from outside (reflection scanning) or illuminated from inside by a light source at the end of a lance which is moved into the hollow cylinder 18 from above (transmission scanning). The scanning element, the illumination lance, a movable cover for the copy cylinder 16 and further constituent parts of the drum scanner 2 are not illustrated in the figures, in the interest of clarity.
The drum scanner 2 is able to accommodate copy cylinders 16 with various diameters, such as 150 mm and 212 mm diameters in this example.
Adhesively bonded to the outside of each copy cylinder 16 , at a suitable location, is a barcode label, which bears a barcode as an optical file name. The drum scanner 2 has a non-illustrated barcode reader, which is able to read the barcode from a copy cylinder 16 when the latter is located in the drum scanner 2 and is rotating.
For operating the drum scanner 2 with the loading magazine 4 , a cylinder transport carousel 24 (FIG. 2) is screwed onto the front side of the casting 10 wherein the spindle 12 is mounted. The cylinder transport carousel 24 has a stationary base, wherein a spindle 26 with a vertical axis of rotation is mounted, and also devices for rotating and for lifting and lowering the spindle 26 , i.e., electric motors and force transmission elements, for example, gear wheels and cam disks, which are otherwise not illustrated in detail.
Fixed to the upper end of the spindle 26 is a rotary plate 30 . The rotary plate 30 has four outriggers 32 , which are arranged symmetrically around the spindle 26 and extend in a common horizontal plane. Each outrigger 32 includes an incompletely closed annular element which, on one side, has a gap and, on the other side, is fixed to the rotary plate 30 . The internal diameter of each outrigger 32 is somewhat smaller than the diameter of the flange 20 of the smallest copy cylinder 16 that is used, so that the outrigger 32 can engage under the flange 20 of a copy cylinder 16 in order to lift it. Each outrigger 32 is fitted to the rotary plate 30 so that it can be folded upwardly and inwardly in order to mount and dismount, or assemble and disassemble, the loading magazine 4 .
As shown in FIGS. 1 and 3, the loading magazine 4 has a frame having one or more rubber feet 34 . The top of the loading magazine 4 is an approximately circular table 36 . In three of four positions which are distributed symmetrically around the center of the table 36 , magazine spaces 38 are formed in the table 36 , and a cutout 40 in the table 36 is formed in the fourth position. Each magazine space 38 is shaped so that a copy cylinder 16 placed therein from above is held upright and centered at the same time. In addition, each magazine space 38 is surrounded by an approximately annular trough 42 , which has approximately the shape of an outrigger 32 on the rotary plate 30 , but is somewhat larger in order to be able to accommodate the outrigger 32 .
The table 36 or the three magazine spaces 38 therein are of such height that copy cylinders 16 (note FIG. 3, for example) located in the respective magazine spaces 38 are held at the same height as a copy cylinder 16 which is located on the spindle 12 of the drum scanner 2 .
In order to mount the loading magazine 4 on or assemble it with the drum scanner 2 , initially, the cylinder transport carousel 24 is screwed onto the casting 10 of the drum scanner 2 . The outriggers 32 on the rotary plate 30 of the loading magazine 4 are folded up, and the loading magazine 4 is pushed horizontally against the drum scanner 2 and connected mechanically to the drum scanner 2 in a position wherein the spindle 12 of the drum scanner 2 is located in the cutout 40 in the table 36 . At the same time, the three magazine spaces 38 of the loading magazine 4 , and the spindle 12 of the drum scanner 2 , are at exactly equal distances on the circumference of a circle around the axis of the cylinder transport carousel 24 . The outriggers 32 are folded down again, so that they each extend into one of the annular troughs 42 (note FIG. 1 ). In addition, an electrical connecting cable 44 (note FIG. 3) from the loading magazine 4 is connected to the drum scanner 2 . The connecting cable 44 is used for transferring data between the drum scanner 2 and the loading magazine 4 . In addition, the connecting cable 44 includes a power supply cable for the loading magazine 4 , which does not have its own power supply and is supplied with power by the drum scanner 2 .
FIG. 4 shows the drum scanner 2 and the loading magazine 4 in the assembled state and with copy cylinders 16 put in place. In this state, the outriggers 32 (seen only partially in FIG. 4 ), respectively, extend without contact into one of the annular troughs 42 (note FIG. 1) at the edge of each magazine space 38 . The rotary plate 30 and the outriggers 32 thereof do not engage the table 36 of the loading magazine 4 , either in the lifted or in the lowered position of the cylinder transport carousel 24 . If the cylinder transport carousel 24 is lifted, then the outriggers 32 lift all the copy cylinders 16 which are in the drum scanner 2 or in the loading magazine 4 . The cylinder transport carousel 24 can then be rotated 90° or a multiple thereof in order to remove a copy cylinder 16 automatically from the drum scanner 2 and transport a different copy cylinder 16 , previously located in the loading magazine 4 , into the drum scanner 2 . If the cylinder transport carousel 24 is lowered again, the copy cylinders 16 are automatically centered on the cone 14 of the spindle 12 or on the magazine spaces 38 . As a result, a given play or freedom is provided for the accuracy with which the relative position between the drum scanner 2 and the loading magazine 4 has to be maintained.
Because the drum scanner 2 and the loading magazine 4 only have to be positioned relative to one another with limited accuracy, it is possible to connect the loading magazine 4 to the drum scanner 2 via damping elements, i.e., connecting elements with vibration-damping properties, instead of rigidly. FIGS. 2 and 4 show such a damping element 46 , which is located in the lower region of the drum scanner 2 and the loading magazine 4 . The damping element 46 includes, for example, a rubber buffer which, at one end thereof, is fixed to the drum scanner 2 and, at the other end thereof, is fixed to a metal angle 48 (note FIG. 3) projecting from the loading magazine 4 when the loading magazine 4 is mounted on the drum scanner 2 . In an upper region of the drum scanner 2 and the loading magazine 4 , at locations 56 (note FIG. 2) on the lefthand and righthand sides of the casting 10 , two further damping elements, which are not visible in the figures, are provided. These damping elements constitute the sole mechanical connection between the drum scanner 2 and the loading magazine 4 , so that they are decoupled, in terms of vibration, from one another.
The damping elements 46 are constructed so as to be stiff enough for the relative position between the loading magazine 4 and the drum scanner 2 to be maintained with the necessary accuracy. In addition, the damping elements 46 are yieldable enough or sufficiently pliant so that any shaking of the loading magazine 4 caused by the operator is as much as possible not transferred to the drum scanner 2 but, via the rubber feet 34 , largely absorbed by the base upon which the devices stand. This makes it possible to take copy cylinders 16 from the loading magazine 4 by hand or to fit the loading magazine 4 with copy cylinders 16 while scanning is taking place in the drum scanner 2 . Without the damping elements 46 , this would not be possible, because the scanning operation can be disrupted even by small shocks.
A non-illustrated mechanical or electronic interlock prevents the rotary plate 30 from being rotated in the lowered state, and the end positions of the “lifting” and “lowering” of the spindle 26 , and the angular position of the rotary plate 30 , are monitored by light barriers or sensors, which are likewise non-illustrated. In addition, a safety device is provided which ensures that the loading magazine 4 can be activated only when the drum scanner 2 is at a standstill and the cover is opened.
FIG. 5 is a detailed sectional view of the table 36 of the loading magazine 4 in the region of a magazine space 38 . A copy cylinder 16 , of which only the lower flange 20 is shown in FIG. 5, is about to be placed on the table 36 . The copy cylinder 16 shown in FIG. 5 is a copy cylinder with a larger diameter than the copy cylinder 16 of FIGS. 2 to 4 . It is possible to see in FIG. 5 the tubular extension 22 on the flange 20 , wherein the internal taper 50 is formed which fits onto the cone 14 of the spindle 12 in the drum scanner 2 . To the bottom of the flange 20 of the copy cylinder 16 , a ring 52 is also integrally molded, and has a greater diameter than that of the tubular extension 22 and, on the underside thereof, has an annular supporting face 54
At a location in the annular space between the tubular extension 22 and the integrally molded ring 52 , a flat transponder 58 is seated in a holder 60 which is adhesively bonded to the flange 20 . Fitted to the magazine space 38 is an annular coil unit 62 having a radius corresponding approximately to the distance of the transponder 58 from the axis of the copy cylinder 16 . The coil unit 62 extends parallel to the table 36 and can be moved vertically a predetermined distance relative to the latter, being forced upwardly by a number of springs 64 , of which only one is shown in FIG. 5 . The coil unit 62 has an annular winding space 66 containing a wire winding.
When the copy cylinder 16 is placed into the magazine space 38 , its dead weight presses the coil unit 62 downwardly counter to the force of the springs 64 , so that the coil unit 62 bears on the transponder 58 , as shown in FIG. 5 .
The transponder 58 includes a freely programmable memory chip, wherein an electronic code and any further data can be stored, such as, for example, other identification features of the copy cylinder 16 , or user-specific data, such as, comments, for example. This data can be read or rewritten with the aid of the coil unit 62 . To this end, suitable high-frequency signals are applied to the wire winding of the coil unit 62 . The wire winding of the coil unit 62 forms an antenna for transmitting the high-frequency signals to the transponder 58 . The transponder 58 also obtains the power supply for the memory chip from the energy of the high-frequency signals. Suitable transponders can be obtained in the marketplace, for example, from the firms TEMIC, PHILIPS, TIRIS and EM MICROELECTRONIC-MARIN.
The circular shape of the coil unit 62 , in conjunction with the defined distance between the transponder 58 and the coil unit 62 , results in there always being good and defined electromagnetic coupling between the transponder 58 and the coil unit 62 , regardless of the angular orientation of the copy cylinder 16 about the axis thereof, so that the data can be read or rewritten reliably in any position. This means that the instant a copy cylinder 16 is located in any magazine space 38 of the loading magazine 4 , it can be identified at any time, and the data stored in the transponder 58 are also available for the acquisition of operating data.
Reading and writing the data stored in the transponder 58 , regardless of position, is also possible when the annular coil unit 62 has a radius which is greater than the distance of the transponder 58 from the longitudinal axis of the copy cylinder 16 , so that the transponder 58 is located within the radius of the coil unit 62 , without making contact therewith, in any position of the copy cylinder 16 .
The transponder 58 in each copy cylinder 16 , and the coil unit 62 at each magazine space 38 , permit the automatic detection or identification of copy cylinders 16 in the loading magazine 4 . Identification can be carried out automatically and without any deliberate action by the operator. As a result, time-saving operating sequences are possible, wherein the operator has to be active at the scanner at significantly greater time intervals than hitherto, long time intervals remaining between phases of operator activity, wherein the operator can perform other activities. Nevertheless, the operator can change copy cylinders 16 in the loading magazine 4 at any time without incurring a risk of confusing the operating sequence. This results from the following description of details of the operation of the drum scanner 2 with loading magazine 4 , and the description of a specific operating sequence for scanning a number of copy cylinders 16 .
As described, the copy cylinders 16 have an optical file name in the form of a barcode label. This label is conventionally the governing code, which is read after the insertion of a copy cylinder 16 into the drum scanner 2 . For this purpose, the copy cylinder 16 is rotated by an electric motor, and the barcode is therefore led past the barcode reader. By using the barcode, the scanner control system can identify the copy cylinder 16 before it carries out its scanning with associated parameters.
If the drum scanner 2 is expanded by the loading magazine 4 , it permits identification of the additional electronic file number of the copy cylinder 16 automatically in the loading magazine 4 , as well. In order to read the barcode label in the loading magazine 4 , either the operator would have to be active, or complicated technical aids would be needed in order to rotate the copy cylinder 16 in the loading magazine 4 and, at the same time, to scan the barcode label.
This applies as well for other additional devices than the loading magazine 4 , for example, copy mounting units. Additional devices of this type can likewise be provided with an annular coil unit 62 for reading the data in the transponders 58 or for writing data into the transponders 58 of copy cylinders 16 . In this way, the copy cylinders 16 can also be identified in the context of operating pre-preparation or post-preparation, or within the context of the acquisition of operating data, even outside the drum scanner 2 .
Because of the annular shape of the coil unit 62 , the operator who places a copy cylinder 16 into the loading magazine 4 or another additional device does not have to take any notice of the position of the copy cylinder 16 . Nevertheless, the transponder 58 may be located off-center on the copy cylinder 16 . A central arrangement would not be possible, because the center of the flange 20 on the copy cylinder 16 is used as a guide.
In order that the use of the loading magazine 4 be compatible with conventional operating sequences, the barcode label is still used as the master, i.e., as the governing or decisive file name. The electronic file name is matched to the barcode. This means that, in a first step, the number which the barcode label bears is read into the transponder. This can be done, for example, by setting the appropriate copy cylinder 16 onto the loading magazine 4 by hand at any desired position. The copy cylinders 16 are then transported in any desired sequence, with the aid of the cylinder transport carousel 24 , into the drum scanner 2 , where the barcode label is read. In addition, the diameter of copy cylinders 16 in the loading magazine 4 or in the drum scanner 2 can be detected automatically, for example, by light barriers. If a copy cylinder 16 which the drum scanner 2 cannot process is mistakenly put into the loading magazine 4 , an error message is produced at the latest when it is detected in the drum scanner 2 .
The identified copy cylinder 16 is conveyed back to a free magazine space 38 where, with the aid of the coil unit 62 , the same number as on the barcode label is written into the transponder 58 . If the barcode label of a copy cylinder 16 is later changed for any reason, then the new barcode label will be detected at the latest during the next scanning of this copy cylinder 16 , whereupon the transponder 58 will be corrected appropriately.
After all the copy cylinders 16 have been provided with an electronic file name, they can be loaded into the drum scanner 2 in agreement with a preprogrammed operating sequence. In this regard, the electronic file name and the barcode of each copy cylinder 16 are compared with one another once more. If they are identical, scanning is carried out, and if they are not identical, the copy cylinder 16 is taken out into the loading magazine 4 again, where its transponder 58 is rewritten.
After the processing of a given copy cylinder 16 in the drum scanner 2 , the cylinder transport carousel 24 is used for exchanging the respective copy cylinder 16 for the next copy cylinder 16 which is to be scanned in accordance with the preprogrammed operating sequence. When the preprogrammed operating sequence has been completed, after the processing of a given copy cylinder 16 , the operation of the drum scanner 2 is stopped and the operator is able to remove the processed copy cylinders 16 from the drum scanner 2 and/or the loading magazine 4 .
A scanned copy cylinder 16 can be scanned once more at a later time, for example, with a higher resolution. The operator can also remove the copy cylinder 16 from the loading magazine 4 in the meantime, for example, in order to have a different copy cylinder 16 scanned in the interim. Subsequent reinsertion can in this case even take place at a different magazine space 38 than the original one. As a result, the operating sequence can be configured very flexibly.
For example, a number of copy cylinders 16 can initially be subjected to a prescan, by being conveyed after one another onto the holding and rotating device of the drum scanner 2 with the aid of the cylinder transport carousel 24 and, after the prescan, being conveyed back to a free magazine space 38 in the loading magazine 4 . After the definition of the parameters for a fine scan of the copy cylinders 16 based upon the data obtained during the prescan, the copy cylinders 16 are subjected to fine scanning, by being conveyed one after another into the drum scanner 2 with the aid of the cylinder transport carousel 24 , being scanned therein and subsequently being conveyed back to a free magazine space 38 in the loading magazine 4 .
In the exemplary embodiment, a maximum of four copy cylinders 16 can be loaded, respectively, one copy cylinder 16 being directly accessible by the drum scanner 2 . This arrangement is particularly beneficial with regard to so-called copix operation, wherein a color set of four individual color separations has to be scanned. Because four copy cylinders 16 with the individual color separations can be fitted together, the result is a particularly smooth operating sequence.
One example of such an operating sequence is shown in FIG. 6 b , while FIG. 6 a shows a corresponding operating sequence if no loading magazine 4 is used. FIGS. 6 a and 6 b are timing diagrams, the first line A of which, respectively, shows blocks representing time intervals during which the operator has to be active, namely for cylinder change W and for prescan processing. A second line B, respectively, shows blocks which represent time intervals during which the drum scanner 2 operates. A third line C indicates which of four cylinders is currently being processed.
In the operating sequence of FIG. 6 b , the loading magazine 4 is activated automatically when the drum scanner 2 is switched on. The loading magazine 4 is filled by the operator of the workstation which controls the drum scanner 2 and the loading magazine 4 . The operator places a copy cylinder 16 , which is to be processed, in any desired magazine space 38 . An electronic compartment interrogation system interrogates this magazine space 38 and reports the respective compartment occupancy to the workstation, the occupancy being detected, for example, by light barriers or sensors, as well as the electronic file name of the copy cylinder 16 which is read by the coil unit 62 . The insertion and the changing, respectively, of a copy cylinder 16 can be detected either by the magazine spaces 38 being interrogated repeatedly at short intervals, or by a light barrier or a sensor which reports a change. The reported data are displayed on a monitor in the work station. In the monitor display, the operator can select a desired copy cylinder 16 and the file name thereof, respectively, whereupon this copy cylinder 16 is transported into the drum scanner 2 by the cylinder transport carousel 24 , as described hereinabove, or is exchanged for a copy cylinder 16 already located in the drum scanner 2 , and is subsequently scanned. After four cylinders have been inserted in this manner and have been subjected to a prescan, the operator having set the parameters for the fine scan on the monitor, all the fine scans are carried out automatically.
As can be seen from a comparison of FIGS. 6 a and 6 b , the overall time of the operating sequence is not reduced by the loading magazine 4 . However, the activity of the operator in FIG. 6 b is concentrated into a coherent time interval and, during the fine scan, he or she can, for example, operate a further scanner.
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In a combination of a drum scanner and a loading magazine, the drum scanner includes a holding and rotating device equipped for holding an interchangeable copy cylinder firmly from below in an at least approximately upright position and for rotating it about a longitudinal axis thereof for scanning. The loading magazine is constructed for containing a plurality n of magazine spaces equipped for holding copy cylinders in the same orientation and at the same height as on the holding and rotating device of the drum scanner, the n magazine spaces and the holding and rotating device being arranged at regular intervals around a cylinder transport carousel having n+1 outriggers extending in a star-shaped manner relative to the n magazine spaces and the holding and rotating device, and being equipped for lifting, together with the aid of the outriggers, copy cylinders located in the n magazine spaces and on the holding and rotating device, respectively, for moving them in a circle and for setting them down again at a desired location. The drum scanner and the loading magazine are subassemblies separably connected mechanically to one another by connecting elements with vibration-damping properties, and being, respectively, provided with at least one foot for bearing the weight virtually of the respective subassembly.
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REFERENCE TO CO-PENDING APPLICATION(S)
The present application is a continuation of U.S. Provisional Patent Application Ser. No. 61/630,555, filed on Dec. 14, 2011 which is related to U.S. Provisional Patent Application Ser. 61/629,318 filed on Nov. 16, 2011, the entire disclosures of which are hereby incorporated by reference.
TECHNICAL FIELD
The present invention relates to the field of portable devices and more particularly to portable devices comprising a biometric sensor arrangement for measuring one or more intrinsic physical or health characteristic of a human.
BACKGROUND OF THE INVENTION
The autonomic nervous system (ANS) regulates “involuntary” organs, while the contraction of voluntary (skeletal) muscles is controlled by somatic motor nerves. Examples of involuntary organs include respiratory and digestive organs, and also include blood vessels and the heart. Often, the ANS functions in an involuntary, reflexive manner to regulate glands, to regulate muscles in the skin, eye, stomach, intestines and bladder, and to regulate cardiac muscle and the muscle around blood vessels, for example.
The ANS includes the sympathetic nervous system and the parasympathetic nervous system. The sympathetic nervous system is affiliated with stress and the “fight or flight response” to emergencies. Among other effects, the “fight or flight response” increases blood pressure and heart rate to increase skeletal muscle blood flow, and decreases digestion to provide the energy for “fighting or fleeing.” The parasympathetic nervous system is affiliated with relaxation and the “rest and digest response” which, among other effects, decreases blood pressure and heart rate, and increases digestion to conserve energy. The ANS maintains normal internal function and works with the somatic nervous system. Afferent nerves convey impulses toward a nerve center, and efferent nerves convey impulses away from a nerve center.
The heart rate and force is increased when the sympathetic nervous system is stimulated, and is decreased when the sympathetic nervous system is inhibited (the parasympathetic nervous system is stimulated). Cardiac rate, contractility, and excitability are known to be modulated by centrally mediated reflex pathways. Baroreceptors and chemoreceptors in the heart, great vessels, and lungs, transmit cardiac activity through vagal and sympathetic afferent fibers to the central nervous system. Activation of sympathetic afferents triggers reflex sympathetic activation, parasympathetic inhibition, vasoconstriction, and tachycardia. In contrast, parasympathetic activation results in bradycardia, vasodilation, and inhibition of vasopressin release. Among many other factors, decreased parasympathetic or vagal tone or increased sympathetic tone is associated with various arrhythmias genesis, including ventricular tachycardia and atrial fibrillation.
Stimulating the sympathetic and parasympathetic nervous systems can have effects other than heart rate and blood pressure. For example, stimulating the sympathetic nervous system dilates the pupil, reduces saliva and mucus production, relaxes the bronchial muscle, reduces the successive waves of involuntary contraction (peristalsis) of the stomach and the motility of the stomach, increases the conversion of glycogen to glucose by the liver, decreases urine secretion by the kidneys, and relaxes the wall and closes the sphincter of the bladder. Stimulating the parasympathetic nervous system (inhibiting the sympathetic nervous system) constricts the pupil, increases saliva and mucus production, contracts the bronchial muscle, increases secretions and motility in the stomach and large intestine, and increases digestion in the small intention, increases urine secretion, and contracts the wall and relaxes the sphincter of the bladder. The functions associated with the sympathetic and parasympathetic nervous systems are many and can be complexly integrated with each other.
Neural stimulation can be used to stimulate nerve traffic or inhibit nerve traffic. An example of neural stimulation to stimulate nerve traffic is a lower frequency signal (e.g. within a range on the order of 20 Hz to 50 Hz). An example of neural stimulation to inhibit nerve traffic is a higher frequency signal (e.g. within a range on the order of 120 Hz to 150 Hz). Other methods for stimulating and inhibiting nerve traffic have been proposed. According to various embodiments of the present subject matter, sympathetic neural targets include, but are not limited to, a peroneal nerve, a sympathetic column in a spinal cord, and cardiac post-ganglionic sympathetic neurons. According to various embodiments of the present subject matter, parasympathetic neural targets include, but are not limited to, a vagus nerve, a baroreceptor, and a cardiac fat pad. Neural stimulation can be selectively delivered to afferent neural pathways, selectively delivered to efferent neural pathways, or delivered to both afferent and efferent neural pathways. For example, some embodiments selectively stimulate or inhibit only parasympathetic afferents or only parasympathetic efferents, and some embodiments selectively stimulate or inhibit sympathetic afferents or efferents.
The present subject matter can be used to prophylactically or therapeutically treat various diseases by modulating autonomic tone. Examples of such diseases or conditions include hypertension, cardiac remodeling, and heart failure.
Hypertension is a cause of heart disease and other related cardiac co-morbidities. Hypertension occurs when blood vessels constrict. As a result, the heart works harder to maintain flow at a higher blood pressure, which can contribute to heart failure. Hypertension generally relates to high blood pressure, such as a transitory or sustained elevation of systemic arterial blood pressure to a level that is likely to induce cardiovascular damage or other adverse consequences. Hypertension has been defined as a systolic blood pressure above 140 mm Hg or a diastolic blood pressure above 90 mm Hg. Consequences of uncontrolled hypertension include, but are not limited to, retinal vascular disease and stroke, left ventricular hypertrophy and failure, myocardial infarction, dissecting aneurysm, and renovascular disease. A large segment of the general population, as well as a large segment of patients implanted with pacemakers or defibrillators suffer from hypertension. The long term mortality as well as the quality of life can be improved for this population if blood pressure and hypertension can be reduced. Many patients who suffer from hypertension do not respond to treatment, such as treatments related to lifestyle changes and hypertension drugs.
Following myocardial infarction (MI) or other cause of decreased cardiac output, a complex remodeling process of the ventricles occurs that involves structural, biochemical, neurohormonal, and electrophysiologic factors. Ventricular remodeling is triggered by a physiological compensatory mechanism that acts to increase cardiac output due to so-called backward failure which increases the diastolic filling pressure of the ventricles and thereby increases the so-called preload (i.e., the degree to which the ventricles are stretched by the volume of blood in the ventricles at the end of diastole). An increase in preload causes an increase in stroke volume during systole, a phenomena known as the FrankStarling principle. When the ventricles are stretched due to the increased preload over a period of time, however, the ventricles become dilated. The enlargement of the ventricular volume causes increased ventricular wall stress at a given systolic pressure. Along with the increased pressure-volume work done by the ventricle, this acts as a stimulus for hypertrophy of the ventricular myocardium. The disadvantage of dilatation is the extra workload imposed on normal, residual myocardium and the increase in wall tension (Laplace's Law) which represent the stimulus for hypertrophy. If hypertrophy is not adequate to match increased tension, a vicious cycle ensues which causes further and progressive dilatation. As the heart begins to dilate, afferent baroreceptor and cardiopulmonary receptor signals are sent to the vasomotor central nervous system control center, which responds with hormonal secretion and sympathetic discharge. It is the combination of hemodynamic, sympathetic nervous system and hormonal alterations (such as presence or absence of angiotensin converting enzyme (ACE) activity) that ultimately account for the deleterious alterations in cell structure involved in ventricular remodeling. The sustained stresses causing hypertrophy induce apoptosis (i.e., programmed cell death) of cardiac muscle cells and eventual wall thinning which causes further deterioration in cardiac function. Thus, although ventricular dilation and hypertrophy may at first be compensatory and increase cardiac output, the processes ultimately result in both systolic and diastolic dysfunction (decompensation). It has been shown that the extent of ventricular remodeling is positively correlated with increased mortality in post-MI and heart failure patients.
Heart failure refers to a clinical syndrome in which cardiac function causes a below normal cardiac output that can fall below a level adequate to meet the metabolic demand of peripheral tissues. Heart failure may present itself as congestive heart failure (CHF) due to the accompanying venous and pulmonary congestion. Heart failure can be due to a variety of etiologies such as ischemic heart disease. Heart failure patients have reduced autonomic balance, which is associated with LV dysfunction and increased mortality. Modulation of the sympathetic and parasympathetic nervous systems has potential clinical benefit in preventing remodeling and death in heart failure and post-MI patients. Direct electrical stimulation can activate the baroreflex, inducing a reduction of sympathetic nerve activity and reducing blood pressure by decreasing vascular resistance. Sympathetic inhibition and parasympathetic activation have been associated with reduced arrhythmia vulnerability following a myocardial infarction, presumably by increasing collateral perfusion of the acutely ischemic myocardium and decreasing myocardial damage.
The prior art teaches many way of measuring heart rate. A stethoscope is traditionally used to amplify these sounds and present them to a caregiver. The acoustic principle may also be used in other ways, both manual and automated, at various parts of the body. Another way is the pulse oximeter approach. In pulse oximeters, a light of a known frequency through an area of the body, such as the fingertip or earlobe, and detect the same light once it has either passed through the body or been reflected back to a photo sensor. With each heart beat, oxygen-rich blood is momentarily pushed through the capillaries in that region. This momentary increase in the oxygen content of the blood upon each heart beat changes the optical properties of the blood. As the light passes through the fingertip or earlobe, specific frequencies are absorbed to varying degrees, depending on the amount of oxygen in the blood, and are therefore not present in the returning light. The change in detected frequencies occurring once per heart beat allows for detection of individual heart beats, and thus a heart rate measurement. The degree of spectral change is used to determine the oxygen content in the blood. Another measurement method makes use of the varying outward pressure applied against the skin by major arteries. With each heart beat, a surge of blood passes through the arteries. In an artery of sufficient size, and located near to the surface of the body, this momentary pressure can be detected by holding a pressure sensor, such as a piezo-electric (P-E) element, in place over the artery location. The P-E element is physically stretched by the momentary outward pressure of the artery during a heart-beat. As it is stretched, the altered shape of the P-E element changes its electrical characteristics—e.g., a change in its resistance to a current passing through it. Changes in the resistance of the P-E are then detected by appropriate circuitry, and used to identify heart beats and thus heart rate. Suitable surface arteries and sensing devices are well known in the art and include sensing at the wearer's wrist, the temple, the inner ear, or the bridge of the nose.
Heart rate monitoring using the chest strap method has become increasingly popular for sports and fitness training as well as for some other activities such as relaxation training, stress relief and meditation in which heart rate as a bio-feedback item has been found useful. During this time, the chest strap has remained in much the same form, as a practical means of obtaining a continuous, accurate heart rate reading for these largely non-medical purposes. However, for many users, the chest strap may chafe causing discomfort. Many users find them awkward to put on, uncomfortable to wear, and bothersome to keep handy. In addition, they can be restrictive of good chest expansion and thus restrict full breathing during exercise. For wearers with slender ribs and torsos, the chest strap can slip down out of the proper position and cease to function properly. Stretched across the chest, they are perceived by some as unmanly, or unwomanly, or as interfering with tan lines or undergarments.
There are various physiological factors affecting the autonomic regulation of heart rate: respiration, thermoregulation, hormonal regulation, blood pressure, cardiac output, etc. One of the most important factors is blood pressure. There are special cells in the heart and large blood vessels that sense blood pressure level and send afferent stimulation to the central structures of the ANS that control HR and blood vessel tonus forming a continuous feedback to maintain an optimal level of the blood pressure.
This mechanism is also called baroreflex. It increases HR when blood pressure drops and vice versa and thus maintains a short-term stable blood supply to the vital organs.
One of the best ways to assess the autonomic function is to analyze minute changes in heart rate, which are caused by many factors including regulatory influence of the autonomic nervous system.
A special method of analysis can be applied to recorded heart rate readings. It is called Heart Rate Variability (HRV) analysis. The HRV analysis is a powerful, very accurate, reliable, reproducible, yet simple to do.
It is found that lowered HRV is associated with aging, decreased autonomic activity, hormonal tonus, specific types of autonomic neuropathies (e.g. diabetic neuropathy) and increased risk of sudden cardiac death after acute heart attack.
Other research indicated that depression, panic disorders and anxiety have negative impact on autonomic function, typically causing depletion of the parasympathetic tonus. On the other hand an increased sympathetic tonus is associated with lowered threshold of ventricular fibrillation. These two factors could explain why such autonomic imbalance caused by significant mental and emotional stress increases risk of heart attack followed by sudden cardiac death.
Aside from that, there are multiple studies indicating that HRV is quite useful as a way to quantitatively measure physiological changes caused by various interventions both pharmacological and non-pharmacological during treatment of many pathological conditions having significant manifestation of lowered HRV.
However it is important to realize that clinical implication of HRV analysis has been clearly recognized as a predictor of risk of arrhythmic events or sudden cardiac death after acute heart attack, and as clinical marker of diabetic neuropathy evolution.
Nevertheless, as the number of clinical studies involving HRV in various clinical aspects and conditions grows, HRV remains one of the most promising methods of investigating general health in the future.
There is an ongoing need for an improved system and method for heart rate, heart rate variability, wellness and fitness monitoring that is user friendly and less invasive.
SUMMARY OF THE INVENTION
One object of the invention is to provide a mobile system that monitors the electrical conductivity of the heart for heart rate variability analysis that tracks health changes and be aware of possible health issues on its early stage, wherein a user can track health changes and reveal health trends, react quickly on detected health issues and to help improve overall health and wellness.
A second aspect of the of the invention is to provide a mobile system that monitors the electrical conductivity of the heart for heart rate variability analysis that can determine a person's biological age and optimize anti-aging procedures, wherein a user can track biological age changes over time, get alerted about sudden changes in biological age and ultimately improve life quality and get younger.
A third aspect of the invention is to provide a mobile system that monitors the electrical conductivity of the heart for heart rate variability analysis that assesses current fitness level and measure daily fitness progress, wherein a user can track fitness progress over time, review fitness level on a worldwide scale and compared to other people within a particular age and gender group.
A fourth aspect of the invention is to provide a mobile system that monitors the electrical conductivity of the heart for heart rate variability analysis to monitor and manage stress, build a strong stress-resistance, wherein stress is reduced with biofeedback control, the body is trained to withstand stress attack, and to help normalized blood pressure.
DETAILED DESCRIPTION
Brief Description of the Drawings
The present invention will now be described in more detail with reference to the enclosed drawings, in which:
FIG. 1 shows a block diagram of the overall system comprising of a mobile ECG system a mobile device and backend server.
FIG. 2 shows a flow diagram of the mobile ECG system.
FIG. 3 shows an ECG recorder in the form of a mobile case.
FIG. 4 shows another view of the ECG recorder in the form of a mobile case.
FIG. 5 shows an ECG recorder in the form of headphone and upper arm band.
FIG. 6 shows an Arm Strap/band with sensor opening.
FIG. 7 shows a version of the ECG recorder in the form of a headphone.
FIG. 8 shows a shows a headphone jack that works in conjunction with the headphone.
FIG. 9 shows exemplary health information modules that are being communicated to the user as a result of heart rate variability analysis.
FIG. 10 shows a version of the ECG recorder in the form of a chest patch.
DETAILED DESCRIPTION
The inventive system, in accordance to FIG. 1 , consists of an electrical footprint of the heart or ECG recorder device. The ECG recorder device consists of a microprocessor 12 , power management 15 , dry ECG sensors and processor 14 . The ECG recorder includes wireless interface 11 capable of communicating with client devices 10 such as a mobile device 16 . The mobile device includes software component running on it, interfacing the ECG recorder with a back-end server 17 , with the capability to capture and save ECG data, and analyzes it to obtain a marker for heart rate variability.
In a preferred embodiment, the ECG recorder interfaces with the mobile or cellular phone via Bluetooth wireless communication protocol to mobile device 16 . The ECG recorder can also connect with the mobile device 16 via wireless local area network (WLAN) products that are based on the Institute of Electrical and Electronics Engineers' (IEEE) 802.11 standards such as Wi-Fi.
Customized software application is installed on the mobile device 16 to review physiologic data of a patient and to (a) view the near real-time waveforms remotely (b) remotely review other standard patient data. The customized software can display at least the following physiologic information: ECG Waveform, health assessment metrics such as Overall Health and Wellness, Biological clock, Fitness Level and Stress Level.
The CPU processor 12 comprises a tangible medium, for example read only memory (ROM), electrically erasable programmable read only memory (EEPROM) and/or random access memory (RAM). The processor 12 may also be comprised many known real time clock and frequency generator circuitries, for example the PIC series of processors available from Microchip, of Chandler Ariz. In some embodiments, processor may comprise the frequency generator and real time clock.
In FIG. 2 , the ECG recorder acquires heart electrical footprint or ECG data from the user 21 . The ECG data gets sent to the mobile device 16 , where it gets validated 22 . The mobile device sends the ECG data to the backend server for further analysis 23 . After analysis, the backend server sends the health module information to the mobile 16 where it gets displayed 24 for biofeedback and coaching 25 .
FIG. 3 shows an exemplary ECG recorder in the form of a mobile cover case 32 (also referred to as “cover”). The cover 32 can also be a mechanism that partially covers the mobile device 33 . The cover 32 encompasses at least two electrodes 31 a - b , on its sides or back to establish contact with the user's fingers and/or chest. The electrodes can be made out of stainless steel, silicon nitride and silver-silver chloride, with dimensions between approximately 4 mm to about 10 mm in diameter or in width and height. The two electrodes 31 a - b (positive and negative) may be paired with a third electrode to serve as a reference voltage (ground) for the differential amplifier and to improve common mode noise rejection.
Holding the cover in one hand, e.g., the left hand, the patient makes contact with one electrode, one on one side of the cover which contacts the thumb. The patient then touches the other side of the cover with the other hand, making contact with the other electrode to the other side. ECG and heart rate are thereby recorded for 1 to 5 minutes.
In FIG. 4 , the cover contains electrodes are attached to a microprocessor 41 (MCU), performing bio-signal detection and processing. The MCU 41 is designed with advanced analog front end circuitry and a flexible, powerful digital signal processing structure. It targets bio-signal inputs ranging from uV to mV level and deployed with proprietary algorithms. The Low-Noise-Amplifier and ADC are the main components of the MCU 41 analog front end. It can detect bio-signals and convert them into digital words using a 16-bit high resolution analog digital converter (ADC). The heart of the MCU 41 digital circuit is a powerful system management unit. It is in charge of overall system configuration, operation management, internal/external communication, proprietary algorithm computation, and power management. The MCU 41 also comes with hardwired DSP blocks to accelerate calculations, such as various digital filtering, under the supervision of the system management unit. In other embodiments, the cover 33 is used as a Mobile Heart Rate Monitor for regular and long term usage for applications such as heart rhythm irregularity detection.
According to one aspect shown in FIG. 5 , the invention can be realized as a specially designed headphone 51 , 52 and left extremity strap 54 . The invention encompasses at least two electrodes on the inner or outer right ear (hereafter referred to as ear) and another on the left extremity. The electrodes are made out of stainless steel, silicon nitride or silver-silver chloride, with dimensions between approximately 3 mm to 10 mm in diameter or in width/length. The two electrodes in FIG. 7 , 71 a and b (positive and negative) are paired with a third electrode to serve as a reference voltage (ground) for the differential amplifier and to improve common mode noise rejection. The preferred system features a negative electrode on the right ear and a positive or ground electrode on a strap FIG. 6 , 61 , touching the skin on the lower arm.
According to FIG. 8 , wires connect these electrodes are mated with the main ECG recorder device via a specialized headphone jack. The Jack includes a mini stereo plug 81 . The jack also includes electrical connectors 84 , making connection with the main recorder device, which has circuitry capable of measuring the electrical voltage potential between the electrodes and to detect patterns therein corresponding to individual heart-beats and heart rate variability. EKG, heart rate and heart rate variability are thereby recorded for 1 to 5 minutes, and are reported to the user in various ways.
In another embodiment, the system has two electrodes FIG. 7 , 71 a - b , at least one electrode positioned to be in contact with the skin of the head, including the ear via a headphone or headset, and a second electrode positioned to be in contact either with the skin of the arm at the bicep ( FIG. 5 ) or wrist, or else with the skin of the torso at the waist. The system serves as a headphone for listening to audio from an audio source device such as a portable MP3 player, a radio, a mobile telephone (e.g., cellular, portable, satellite, etc.), etc. An in-the-ear style of headphones, commonly known as “ear-buds”, can be used. Ear-buds are commonly worn one bud in each ear, such that the outer surface of each bud enclosure is in contact with the skin of the folds of the ear. In this embodiment, the outer surface of the bud enclosure is modified to be electrically conductive and made to serve as an electrode connected to the heart-beat detection circuitry. Some ear-bud designs, which are popular among exercisers, also contain a structure designed to fit around the ear, thus holding the ear-bud in place during vigorous physical activity. Such a design may also, in this embodiment, provide contact surfaces around the ear which may be used to hold a conductive surface (electrode) in constant contact with the skin around the ear.
The other electrode can be integrated into a carrying case used for carrying portable audio devices FIG. 6 , 54 . Exercisers who wish to wear a portable audio device (MP3 player, radio, mobile telephone, etc.) frequently wear the audio source device in one of several locations: strapped to the upper arm, strapped to the wrist or forearm, clipped to the waistband of exercise clothing, held in the hand, etc. Features and aspects hereof may include an apparatus which holds the portable audio source device and the heart rate detection circuit in one of those convenient locations and integrates a conductive surface at that location to serve as one of the required electrodes connected to the heart rate detection circuit.
HRV is being used to derive health assessment metrics, FIG. 9 such as overall health and wellness 91 , aging 92 , fitness 94 and stress 93 . The source information for HRV analysis is continuous beat-by-beat (not averaged) recording of heartbeat intervals. The electrical footprint of the heart or Electrocardiograph (ECG or EKG) is considered as the best way to measure heartbeat intervals. ECG is an electrical signal reflecting minute changes in the electrical field generated by heart muscle cells. It is measured by a special electronic device with conductive electrodes placed on chest around heart area or limbs. ECG signal has a very specific and robust waveform simple to detect and analyze. Cardiac rhythm (sequence of heartbeat intervals) derived from ECG is the best way to detect normal heartbeats as well as all sorts of ectopic heartbeats, which must be excluded from the HRV analysis.
The autonomic nervous system function can be evaluated with the Autonomic Balance Test. This test is based on the short-term HRV analysis of resting heart rate recordings of 1 to 5 minutes long. Such recordings are assumed to be done at a steady-state physiological condition and should be properly standardized to produce comparable results.
According to the standards set forth by the Task Force of the European Society of Cardiology and North American Society of Pacing and Electrophysiology in 1996, there are two methods of analysis of HRV data: time- and frequency-domain analysis. For both methods the heartbeat intervals should be properly calculated and any abnormal heartbeats found. HRV relates to the regulation of the sinoatrial node, the natural pacemaker of the heart by the sympathetic and parasympathetic branches of the autonomic nervous system. An HRV assessment is based on the assumption that the beat-to-beat fluctuations in the rhythm of the heart provide us with an indirect measure of heart health, as defined by the degree of balance in sympathetic and vagus nerve activity.
The ECG recorder collects ECG data from users which gets analyzed and converted to HRV data the gives information about different states of the Autonomic Nervous System. It happens that ANS states vary from one individual to another, especially of different age and gender. The backend server 17 matches the state of the user's Autonomic Nervous System to the range of “healthy” states of individuals of within the age range and gender. The correct results about your health 91 and fitness 94 are determined.
Fitness assessment 94 is based on the one of the most accurate methods of fitness assessment. Analysis is done on ECG signal at the backend server that determines the autonomic nervous system's response on a simple standup maneuver. The standup maneuver causes heart rate to rise within the first 10-15 seconds because blood pressure drops due to gravitational redistribution of the blood mass. Then the cardiovascular system attempts to compensate an orthostatic effect of standing up by constricting peripheral blood vessels. As a result blood pressure returns to its normal level and heart rate drops. Athlete body reaction is fast and strong, while sedentary lifestyle makes body react with a delay and a little amplitude. This serves as a base of determining a fitness level.
This biological clock 92 is determined based on the body's ANS (autonomic nervous system) response on paced breathing. The risk of myocardial infarction and overall health condition of the body is evaluated.
The current invention makes an assessment of the autonomic nervous system regulatory function condition based Autonomic Balance—a ratio between levels of the sympathetic and parasympathetic activity and Autonomic Tonus—a net level of the sympathetic and parasympathetic activity.
There are three main types of the autonomic nervous system conditions: 1—Predominant parasympathetic nervous system function—typical for a state of relaxation, 2—Predominant sympathetic nervous system function—typical for a state of stress and 3—Balanced autonomic nervous system function—typical for an idle calm state.
Each of these three categories may have three different levels of the autonomic tonus: low, normal or high. The Autonomic Balance is calculated in points based on 80% of least deviated values of HRV parameters in the normative database. It ranges from −10 points to +10 points.
To make a conclusion on the HRV analysis, actual ECG readings of all HRV parameters are compared with their respective normal ranges specific to patient's age and gender. These normal ranges are taken from a normative database built in a special clinical study on a large pool of clinically validated healthy subjects.
Normal range is a range of values of certain HRV parameter representing statistical distribution of this parameter values in a large population of healthy individuals of selected age and gender. For instance, the logarithmic value of HF (ms^2/Hz) lies in range between 2.5 and 6.6 for males between 30 and 40 years old.
In this embodiment, a 48 years old male was tested with an autonomic balance test. The test results showed an HF parameter value of 3.1 on logarithmic scale of ms^2/Hz. A predicted value for 48 years old males is 4.03. One of the widely used approaches is determining a normal range based on criteria of statistical distribution of measured parameter values in healthy subjects. Typically normal range is considered within 95% of the interval of confidence in both directions. This range would fit 95% of all readings obtained from healthy subjects of the selected population. It is important to mention that there is a borderline zone (or conditional norm) in near proximity to the borders of the normal range. Actual readings falling into this zone have higher risk to be abnormal ones.
All test results of the healthy subjects tested in a special epidemiologic study were analyzed by separate gender and age groups. For example, all test results of all males of age 30 were put in one group. Predicted values for each HRV parameter were calculated as described above. Then all parameter values (in this example—mean heart rate) were grouped around the predicted values. 5% of the values most deviating from the predicted value are considered as outlying (outside of the normal range). The rest 95% of all values define the normal range.
The ECG recorder considers 15% of the most deviating values among those falling into 95% range as borderline range. Only remaining 80% of all values forms a true normal range used to form an interpretive Autonomic Balance diagram described below. For the subject described in this example a lower borderline level of HF parameter is 2.64. Thus the value shown in the example above falls into a borderline zone.
When using the ECG recorder in FIG. 1 to monitor the dynamics of changes in the autonomic regulatory function or to evaluate the effects of specific factors on this function an important question is usually asked—if the changes in a measured parameter are considered significant or are result of normal variation of the random process. This question is answered based on assessment of the reproducibility and repeatability of the measured parameter. Reproducibility is a variance of a parameter being repeatedly measured in the same subject within a limited time frame. Repeatability reflects natural variance of a specific parameter in the same subject observed during a long period of time (several weeks).
HRV parameters significantly depend on current condition of the subject at a time of testing. Thus it is virtually impossible to obtain absolutely identical readings measured at different moments. This means that the reproducibility and repeatability of the test cannot be 100%. High level of reproducibility and repeatability means only qualitative similarity of any two test results obtained from the same individual at substantially similar conditions of both subject and testing environment. When comparing test results, keep in mind that the autonomic nervous system is fairly sensitive to many internal and external factors including various genetically predetermined and transitory factors, health assessment metrics.
The most appropriate way to assess the autonomic nervous system function is to use so-called predicted values defining normal values of specific HRV parameters, which we expect to obtain from a tested individual if we assume that this individual is healthy. Predicted value is a statistically most probable value of the parameter predicted based on correlation between this parameter values, age and gender of healthy individuals. Predicted values are calculated by the formulae created based on a special study obtained readings from a large population of healthy subjects of different ages and gender.
It's well established that baroreceptor strength declines with age. The reason is that the sensitiveness of the body to any external or internal stimulant makes body easily adaptable to new environment and tells about its strong immunity to fight diseases.
An optimal level of the systemic arterial blood pressure is one of the vital physiological parameters determining adequate function of the cardiovascular system. If arterial pressure is too low then brain, heart and other vital organ do not receive an adequate blood supply so their functions may be affected, e.g. low blood supply to the brain would cause dizziness or even fainting. Alternatively too high arterial pressure causes unnecessary workload to the heart and negatively affects vascular system.
An arterial baroreflex is a key mechanism of short-term regulation of arterial blood pressure. Its whole purpose is to sense minute changes in blood pressure and adjust heart rate to compensate changes in blood supply to the vital organ caused by blood pressure changes. Baroreflex function significantly affects body's ability to adequately react to physical, emotional or mental stressors 93 , which may cause significant changes in blood pressure. Decreased baroreflex function may be an early sign of developing cardiovascular disorders such as arterial hypertension and poor overall health 91 .
The biological clock 92 test involves continued deep breathing following on-screen instructions for about 1 minute. During that time the ECG recorder analyzes reaction of the user's body on deep paced breathing. The more sensitive the body is, the better shape the user is in. This means that the body is capable to react immediately on changes in internal and external environments, which is a good sign of being younger.
During inhalation the chest is expanding and its internal pressure drops leading to a slight drop in blood pressure because large blood vessels inside the chest are stretched when chest is expanded. The baroreflex causes a quick increase in heart rate as described above. During exhalation the chest contracts so its internal pressure rises causing blood pressure to rise as well due to shrinking large blood vessels in the chest. The baroreflex causes a quick decrease in heart rate as described above. This phenomenon is also known as respiratory sinus arrhythmia. Deep breathing causes maximum possible fluctuations in blood pressure, which helps measuring baroreflex function with larger stimuli. It was found that the highest changes in heart rate induced by deep breathing happen when breathing at the rate of about 6 breaths per minute. Measurement of heart rate oscillations when breathing deeply at 6 breaths per minute is a simple yet effective way to measure baroreflex function. The less sensitive baroreflex is the lesser heart rate oscillations occur.
High baroreflex function is a sign of good vascular elasticity and thus ability of the body to efficiently adapt to various physical, emotional and metal factors causing stress 93 and raise of blood pressure. Low baroreflex function typically is a sign of aging process or certain cardiovascular problem causing stiffness or arterial walls.
The time interval between intrinsic ventricular heart contractions changes in response to the body's metabolic need for a change in heart rate and the amount of blood pumped through the circulatory system. For example, during a period of exercise or other activity, a person's intrinsic heart rate will generally increase over a time period of several or many heartbeats. However, even on a beat-to-beat basis, that is, from one heart beat to the next, and without exercise, the time interval between intrinsic heart contractions varies in a normal person. These beat-to-beat variations in intrinsic heart rate are the result of proper regulation by the autonomic nervous system of blood pressure and cardiac output; the absence of such variations indicates a possible deficiency in the regulation being provided by the autonomic nervous system. One method for analyzing HRV involves detecting intrinsic ventricular contractions, and recording the time intervals between these contractions, referred to as the R-R intervals, after filtering out any ectopic contractions (ventricular contractions that are not the result of a normal sinus rhythm). This signal of R-R intervals is typically transformed into the frequency-domain, such as by using fast Fourier transform, so that its spectral frequency components can be analyzed and divided into low and high frequency bands. For example, the low frequency (LF) band can correspond to a frequency (LF range 0.04 Hz to <0.15 Hz, and the high frequency (HF) band can correspond to a frequency range (HF range of 0.15 Hz-0.40 Hz). The HF band of the R-R interval signal is influenced only by the parasympathetic/vagal component of the autonomic nervous system. The LF band of the R-R interval signal is influenced by both the sympathetic and parasympathetic components of the autonomic nervous system. Consequently, the ratio LF/HF is regarded as a good indication of the autonomic balance between sympathetic and parasympathetic/vagal components of the autonomic nervous system. An increase in the LF/HF ratio indicates an increased predominance of the sympathetic component, and a decrease in the LF/HF ratio indicates an increased predominance of the parasympathetic component. For a particular heart rate, the LF/HF ratio is regarded as an indication of patient wellness, with a lower LF/HF ratio indicating a more positive state of cardiovascular health. A spectral analysis of the frequency components of the R-R interval signal can be performed using a FFT (or other parametric transformation, such as auto-regression) technique from the time domain into the frequency domain. The LF/HF ratio will be used to provide the WM. The LF/HF will be compared to standardized numbers to approximate wellness trends for users.
In another embodiment, the WM may be performed by time domain measurements of the ECG signal. In a continuous ECG record, each QRS complex is detected, and the so-called normal-to-normal (NN) intervals (that is, all intervals between adjacent QRS complexes resulting from sinus node depolarizations) or the instantaneous heart rate is determined. The simplest variable to calculate is the standard deviation of the NN intervals (SDNN), that is, the square root of variance. Since variance is mathematically equal to total power of spectral analysis, SDNN reflects all the cyclic components responsible for variability in the period of recording. The HRV measurement will be used, along with at least one parameter such as body weight, to provide a more complete picture of health.
There needs to be a balance between hard and easy training and rest both within a single training week and within longer training periods. When a hard training session or training period that causes a significant disturbance in body's homeostasis is followed by sufficient recovery, performance improvements are likely to occur. The importance of sufficient recovery is due to the fact that performance improvements actually occur during recovery from training, not during workouts. Finding a balance between training load and recovery is a key factor in improving athletic performance.
Recovery is an important factor with any training regimen. Usually athletes have several very hard training periods each year, during which both the intensity and volume of training are very high. These kind of overreaching periods are very exhaustive but necessary for elite athletes to further improve their performance. However, performance can improve only if hard training is followed by adequate recovery.
Too hard training without sufficient rest may lead to overtraining, which is characterized by decreased performance and in the worst case also other harmful effects on health. Recovery from overtraining may take from several weeks to months, but it is also possible that an athlete never reaches the same level of performance as before overtraining. Prevention of overtraining is therefore crucial, and is possible by systematic assessment of the athlete's recovery. Recovery is defined as decreased activation in the body during relaxation, rest and/or peaceful working, related to lack of external and internal stress factors when parasympathetic (vagal) activity is great and sympathetic activity is low. Recovery is detected when HR is close to the resting level and HRV is great and regular according to the breathing rhythm. Level of HRV is individual. This must be taken into account when interpreting the measured data since analysis is based on HRV. It is recommended that reference values are measured for both high training load/poor recovery and for low training load/well recovered conditions. These reference values should be updated whenever needed, for example between different training periods if changes appear in ANS function.
Respiration can be an indicator of activity, and can provide an explanation of increased sympathetic tone. For example, it may not be appropriate to change or modify a treatment for modulating autonomic tone due to a detected increase in sympathetic activity attributable to exercise. Respiration measurements can be used to measure Respiratory Sinus Arrhythmia (RSA). RSA is the natural cycle of arrhythmia that occurs through the influence of breathing on the flow of sympathetic and vagus impulses to the sinoatrial node (parasympathetic nervous system—PNS). The rhythm of the heart is primarily under the control of the vagus nerve, which inhibits heart rate and the force of contraction. The vagus nerve activity is impeded and heart rate begins to increase when a breath is inhaled. When exhaled, vagus nerve activity increases and the heart rate begins to decrease. The degree of fluctuation in heart rate is also controlled significantly by regular impulses from the baroreceptors (pressure sensors) in the aorta and carotid arteries. Thus, a measurement of autonomic balance can be provided by correlating heart rate to the respiration cycle. The bigger the RSA, the better it is for heart function and blood pressure. Short and rapid breathing is associated with small RSA, and slow and long breath with larger RSA. Thus, slow and long breath is helpful in supporting heart function and lowering blood pressure.
Instant bio-feedback can be provided to the patient, without the need for any interruption arising from repositioning of the device. The bio-feedback derived from HRV and RSA can be used in the areas of stress reduction, rehabilitation, performance enhancement, Migraines and other headaches, AIDS, Depression or Bipolar Disease, Anxiety, Post-traumatic Stress Syndrome, Attention Deficit Disorder, Fibromyalgia, Hypertension, Post-MI, Angina, Atherosclerosis, Mitral Valve Prolapse Syndrome, Cardiomyopathy, Cardiac Dysrhythmias, Congestive Heart Failure, Acquired Hypothyroidism, Thyroid Disorders, Premature Menopausal Symptoms, Menopausal Syndromes, Sleep Apnea, Asthma and COPD (this list is not meant to be exhaustive).
The cover 33 may comprise of memory to store signals for delayed transmission. Conveniently, an archive memory may be used to store standard bio-data such as standard ECG trace of the user, acquired when the user is healthy. This archived bio-signal may then be sent to distant medical professions, along with contemporary signals, when the user/patient is having a crisis. The cover 33 may be coupled to the cell phone by an internal or external connector which extends from the circuitry of the cover to the microphone or data port of the cell phone to transfer the bio-signal data to the cell phone. Data may be transferred to mobile phone or client device using wired or wireless communication 11 comprising at least one of Bluetooth, Zigbee, WiFi, WiMax, IR, a cellular protocol, amplitude modulation or frequency modulation such as Bluetooth, ANT, zigbee and radio. The client device 10 can be a Personal Digital Assistant (PDA), mobile phone, a telehealth hub, laptop computer, personal computer and server. The cover 33 may be powered by its own internal battery source 15 or may piggyback on the power supply of the mobile device. In another embodiment, the power supply 15 is a rechargeable power supply, and more particularly, a rechargeable battery power supply.
In addition to HRV and RSA the ECG recorder can include and/or connected to other sensors and devices that include blood glucose meter, a pacemaker, a blood pressure monitor, an insulin pump, a pulse oximeter, a holter monitor, an electrocardiograph, an electroencephalograph, a blood alcohol monitor, an alcohol breathalyzer, an alcohol ignition interlock, a respiration monitor, an accelerometer, a skin galvanometer, a thermometer, a patient geo-location device, a scale, an intravenous flow regulator, patient height measuring device, a biochip assay device, a sphygmomanometer, a hazardous chemical agent monitor; an ionizing radiation sensor; a monitor for biological agents, a loop recorder, a spirometer, an event monitor, a prothrombin time (PT) monitor, an international normalized ratio (INR) monitor, a tremor sensor, a defibrillator, or any other medical device.
An application programming interface (API) may be used to access data of many different types. In one implementation, the API may be used for bi-directional communication between the wellness cover device and other medical devices for updating and deleting data and metadata.
Beyond a cover, the ECG recorder in FIG. 1 may also be incorporated into a harness, patch/band aid or glove, communicating with mobile or cell phone or client devices, in order to convey the bio-signal into the telephonic transmission portion of the combined device.
In another embodiment, FIG. 10 shows the ECG recorder in the form of a patch. The patch has a soft breathable cover 101 . Underneath the breathable cover 101 is a waterproof electronics housing 102 , which houses the electronics 104 , battery 103 on a flexible circuit board 108 . The patch has a flexible backing 110 . Electrical leads 107 are attached onto dry ECG sensors 106 , running along the breathable, flexible backing 110 , which contains adhesive that adheres to the user.
The present invention has now been described with reference to exemplifying embodiments. However, the invention is not limited to the embodiments described herein. On the contrary, the full extent of the invention is only determined by the scope of the appended claims.
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The invention is directed to a system for acquiring electrical footprint of the heart, electrocardiogram (EKG or ECG) and heart rate variability monitoring, incorporated into a mobile device accessory. The ECG signal is conveniently acquired and transmitted to a server via the mobile device, offering accurate heart rate variability biofeedback measurement which is portable and comfortable during normal daily life. The invention provides a reliable tool for applications such as wellness, meditation, relaxation, sports and fitness training, and stress-relief therapy where accurate heart rate variability measurement is desired.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to electronic door locks, and more particularly to an override mechanism for unlatching or opening an electronic door mortise lock from an electronically controlled locked side in instances when the electronic door lock cannot or should not be unlocked electronically.
[0003] 2. Description of Prior Art
[0004] Electronic door mortise locks having an electronically controlled locked door side and an unlocked door side are generally used to lock doors of hotel rooms and the like. Such door locks generally comprise a lever handle on the locked door side which remains locked and a lever handle on the unlocked door side which remains unlocked. An electronic mechanism such as a magnetic card reader is generally mounted to the locked door side such that a user having access to a magnetic card programmed to be recognized by the magnetic card reader can unlatch the lock from the locked door side. Such a mechanism is often powered by a battery connected thereto and is not accessible from the locked door side, for safety reasons.
[0005] A problem with such electronic door locks occurs when the battery goes dead or when the electronic mechanism becomes defective. In such cases, the electronic door lock fails to operate and the lock cannot be unlatched, preventing the door from being opened.
SUMMARY OF THE INVENTION
[0006] One aim of the present invention is to provide an override mechanism which unlatches such an electronic door mortise lock from the electronically controlled locked side and which does not require modifications to the integrity of the lock.
[0007] In accordance with a broad aspect of the present invention, there is provided in an electronic door mortise lock having an electronically controlled locked side and an unlocked side, an override mechanism for unlatching the electronic door mortise lock from the electronically controlled locked side. The override mechanism comprises an interior drive mechanism connected to a door handle input hub of the unlocked side for driving the door handle input hub from a closed position to an open position and a locking mechanism accessible from said electronically controlled locked side and adapted to actuate the interior drive mechanism.
[0008] The locking mechanism may comprise an exterior drive mechanism connected to the interior drive mechanism for mechanically driving the interior drive mechanism from the electronically controlled locked side, and actuation of the exterior drive mechanism actuates the interior drive mechanism and drives the door handle input hub from the closed position to the open position, thereby unlatching the electronic door mortise lock from the electronically controlled locked side.
[0009] The exterior drive mechanism may comprise a cylinder lock connected to a tailpiece, and the locking mechanism may comprise a key.
[0010] The interior drive mechanism may comprise a gear mechanism having a spur gear connected to the tailpiece and a rotatable rack member connected to the lever handle input hub, and the gear mechanism may provide a gear ratio between the cylinder lock and the input hub of at least 3:1, and preferably of at least 5:1.
[0011] The cylinder lock and spur gear may rotate less than one turn to unlatch the door lock. The spur gear may be free to rotate without the tailpiece when the door handle is turned from the inside, and the tailpiece may drive the spur gear when the cylinder lock is rotated.
[0012] The gear mechanism may comprise a geared portion of a stop plate connected to a lever handle of the unlocked side.
[0013] The override mechanism may further comprise a detector for detecting actuation of the interior drive mechanism and an output for connecting the detector to the electronic door lock. Such a detector may comprise a cam connected to the tailpiece and having an outside rim, and a switch disposed adjacent the cam such that the switch is activated when the tailpiece is actuated, whereby when the cam is rotated with the tailpiece, the outside rim contacts the switch, thereby generating a signal indicative of actuation of the interior drive mechanism.
[0014] The interior drive mechanism may comprise a gear mechanism comprising a spur gear engaged with a geared portion of a lever handle stop plate connected to the lever handle input hub.
[0015] The override mechanism of the present invention allows a user having privileged access to unlock the electronic door mortise lock from the electronically controlled unlocked door side when the electronic door mortise lock is unlockable electronically, such as when electronic components thereof fail to operate or when the battery goes dead.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof, in which like numerals refer to like components, and in which:
[0017] [0017]FIG. 1 is a side view of an electronic door mortise lock mounted to a door and comprising an embodiment of an override mechanism in accordance with the present invention, showing in housingly breakaway view internal components thereof;
[0018] [0018]FIG. 2 is a plan view of the inside housing of the housing of the electronic door mortise lock and showing the override mechanism in accordance with the present invention;
[0019] [0019]FIG. 3 is a front perspective view of a spur gear of the embodiment of the override mechanism shown in FIG. 2; and
[0020] [0020]FIG. 4 is a rear perspective view of a cam of the embodiment of the override mechanism shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
[0021] Referring now to FIG. 1, there is provided an electronic lock 10 for insertion in a mortise of a door 12 having an exterior door side 14 and an interior door side 15 and for electronically controlling the locking of the exterior door side 14 , while leaving the interior door side 15 unlocked. The electronic lock 10 comprises an override mechanism 16 in accordance with the present invention.
[0022] The electronic lock 10 has a housing assembly 18 including an outside housing 20 mounted to the exterior door side 14 and an inside housing 22 mounted to the interior door side 15 . An outside lever handle 26 outwardly extending from the outside housing 20 and an inside lever handle 28 outwardly extending from the inside housing 22 are mounted to opposed ends of a square spindle 30 extending through the mortise of the door 12 and which is connected to a retractable latch bolt 31 . As mentioned above, the inside housing 22 remains unlocked so that when the inside lever handle 28 is rotated, the square spindle 30 rotates from a closed position to an open position and the latch bolt 31 is retracted inside the mortise of the door 12 from a closed position to an open position.
[0023] As shown in FIG. 2, a lever stop plate 32 is mounted to the square spindle 30 and connected to the inside lever handle 28 . The lever stop plate 32 has a curved rack 34 with eight teeth 36 . A circular spur gear 38 has an opening 39 at the center thereof and twelve spaced apart spurs 40 outwardly extending with respect to an axis going through the opening 39 . The spur gear 38 has its spurs 40 meshed with the teeth 36 of the curved rack 34 . Rotation of the spur gear 38 in the direction indicated by the arrow A moves the lever stop plate 32 from the closed position shown in FIG. 2 to an open position in the direction shown by the arrow B. As shown in FIG. 3, the spur gear 38 has a front surface 42 which defines an annular recess 44 about the opening 39 . An abutment 46 extends radially inwardly in the recess 44 for purposes to be later explained. As seen in FIG. 2, the opening 39 of the spur gear 38 receives a tailpiece 60 extending from a rotatable cylinder lock 62 (FIG. 1) for movement therewith. The cylinder lock 62 is actuatable with a key 64 (FIG. 1) insertable through an opening 66 in the outside housing 20 . The key rotates ⅔ of a turn for retracting the latch bolt 31 . The cylinder lock 62 may be a 6-pin “key-in-knob” such as the cylinder lock from Lori Lock and Rocky Mount, and the key 64 may be a Lockwood 1004 reverse. Mushroom pins (not shown) may be used for at least three pins for increased safety. The torque required on the key 64 will not exceed 9 in-lbs when the latch bolt 31 is projected or when the required torque on the inside lever is 50 in-lbs or less because of warped doors. The cylinder lock 62 may be incorporated in the die of the outside housing 20 . A medallion (not shown) can be used to cover the opening 66 for the keyway.
[0024] The override mechanism 16 is operated when the key 64 is inserted in the opening 66 in the outside housing 20 . Rotation of the key 64 is transmitted to the tailpiece 60 rigidly connected to the cylinder lock 62 and rotates the spur gear 38 , which moves the inside lever stop plate 32 from the closed position as shown in FIG. 2 to the open position as indicated by the arrow B. This causes the latch bolt 31 to retract inside the mortise of the door 12 .
[0025] A detector 48 is included for detecting the actuation of the spur gear 38 . The detector 48 comprises a cam 50 drivingly connected to the tailpiece 60 and having an outside rim 51 . As shown in FIG. 4, the cam 50 has a front surface 52 and a back surface 54 defining a rectangular slot opening 56 at the center thereof for receiving the tailpiece 60 so that a torque can be transferred from the tailpiece 60 to the cam 50 . The back surface 54 thereof is disposed adjacent the front surface 42 of the spur gear 38 . The back surface 54 of the cam 50 defines a circular projection 58 outwardly extending from the plan of the back surface 54 . An abutment 61 projects outwardly from the circular projection 58 with respect to an axis going through the slot opening 56 . As shown in FIG. 2, the abutment 61 is received in the recess 44 on one side of the abutment 46 . When a key is inserted into the cylinder lock 62 and rotated in a clockwise direction, as indicated by arrow A, the tailpiece 60 will rotate the cam 50 in the same direction, thereby causing the abutment 61 to push on the abutment 46 . This will cause the spur gear 38 and, thus, the stop plate 32 to rotate with the cam 50 . The movement communicated to the stop plate 32 will cause the inside lever handle 20 to rotate to retract the latch bolt 31 . However, when the inside lever handle 28 is operated to displace the latch bolt 31 to an open position, the induced counter clockwise rotation of the stop plate 32 will cause the spur gear 38 to rotate in a clockwise direction, thereby displacing the abutment 46 away from the abutment 61 of the cam 50 . Therefore, no motion will be communicated to the cam 50 .
[0026] It is understood that once the override mechanism 16 has been actuated to retract the latch bolt 31 , a biasing force acting, for instance, on the stop plate 32 will bring back the spur gear 38 to its rest position (FIG. 2), thereby causing the abutment 46 to push on the abutment 61 so as to cause the cam 50 to return to its idle position (FIG. 2).
[0027] A switch 70 is disposed adjacent the outside rim 51 of the cam 50 . An output (not shown) is connected to the switch 70 for connecting to the electronic door lock 10 . When the cam 50 is rotated by the tailpiece 60 from its idle position to an operative position, the outside rim 51 or cam surface thereof will trigger the switch 70 , thereby generating a signal indicative of actuation of the override mechanism 16 . Alternatively, the tailpiece 60 can be directly drivingly connected to the spur gear 38 if the detector 48 is not needed.
[0028] While the invention has been described with particular reference to the illustrated embodiment, it will be understood that numerous modifications thereto will appear to those skilled in the art. Accordingly, the above description and accompanying drawings should be taken as illustrative of the invention and not in a limiting sense.
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The present invention relates to electronic door locks, and more particularly to an override mechanism for unlatching an electronic door mortise lock from an electronically controlled locked side when it cannot be unlocked electronically. The override mechanism comprises an interior drive mechanism connected to a door handle input hub of the unlocked side, for driving the door handle input hub from a closed position to an open position, and a locking mechanism adapted to actuate the interior drive mechanism.
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BACKGROUND OF THE INVENTION
In automated storage systems, for example, high rack storage facilities, transport pallets, preferably so-called wooden Euro pallets, are transported automatically by roller conveyors, chain conveyors, rack servicing devices and/or other devices, moved to the desired storage location of the storage system, and removed as needed.
It is known that the employed wooden pallets partially cause significant operational disturbances; in particular by using low quality wood material in the wooden pallets that are supplied from the outside to the storage system, the number and the severity of operational disturbances appear to be increasing.
Even when undamaged wooden pallets are introduced into the storage system, the load on the skids caused by the conveying equipment can lead to damage on the wooden pallets and thus to operational disturbances.
Low quality wooden pallets have generally also relatively strong deviations of their geometry relative to the nominal dimensions set by standards; this also may cause disturbances.
This has the results that, for example, in storage systems that only store their own wooden pallets, particularly expensive wooden pallets of select wood pieces are used. This solution cannot be employed in storage systems that primarily store pallets that are delivered by third parties.
Moreover, in many storage system there is the need to store also pallets with smaller major dimensions than the standard pallets (half pallets, quarter pallets) in a mix with standard pallets.
In order to avoid these problems, DE 42 42 472 A1 discloses a support structure for wooden pallets that is substantially comprised of a shell that is precisely dimensioned to match the bottom side of the wooden pallets. Into this shell the loaded wooden pallet is inserted before entering the storage system and removed again after leaving the storage system. This solution however has not found acceptance in practice.
Known automated storage systems require conventionally the use of pallets with skids, inter alia because of the employed roller conveyors. The use of inexpensive nesting pallets that generally do not comprise skids and therefore cannot be conveyed on roller conveyors is thus impossible.
Plastic pallets with skids that are not provided with special devices, for example, steel reinforcements, also generally cannot be employed in automated storage systems because the deformation caused essentially by creeping of the plastic material may cause operational disturbances. By means of complex auxiliary supports that additionally support the pallets across the bridged length, the problem of deformation can be solved.
At the same time, plastic pallets with skids are basically considered to be operationally safer than wooden pallets because of their geometric integrity and dimensional stability. Therefore, sometimes high-quality plastic pallets are used in automated high rack storage facilities. These expensive pallets are however subject to significant wear.
SUMMARY OF THE INVENTION
The invention has the object to avoid the operational disturbances caused by wooden pallets in automated storage systems and to enable the use even of damaged pallets and the storage of half pallets or quarter pallets. Moreover, the use of nesting transport pallets that usually do not have skids should also be enabled in storage systems of the aforementioned kind.
This object is solved according to the invention by a shuttle pallet for a high rack storage facility that is furnished with storage locations designed for storing goods positioned on pallets, wherein the shuttle pallet comprises three longitudinal supports arranged parallel to one another, at least two load bearing bridges extending orthogonally to the longitudinal supports, wherein the longitudinal supports and the load bearing bridges are connected in articulated fashion with one another.
Advantages of the Invention
By using an additional shuttle pallet, “deficiencies” of the pallets to be stored are eliminated. For example, transport pallets of wood whose dimensions no longer comply with the prescribed standard dimensions or from which smaller parts have been chipped off, can be placed onto the shuttle pallet according to the invention. The transport pallet with the goods stored thereon is then transported together with the shuttle pallet within the automated storage system, for example, by roller conveyors, chain conveyors, rack servicing devices and others, and finally deposited for storage at a storage location and removed again as needed. In this connection, only the shuttle pallet according to the invention is in contact with the roller conveyors, chain conveyors, rack servicing devices, and the storage locations of the storage system, the transport pallet has no direct contact with the storage system so that deficiencies of the transport pallets will not affect the storage system. As a result of this, the deficiencies of the transport pallets can be eliminated and the shuttle pallets according to the invention can be optimized entirely with respect to the requirements of the storage system.
In order to enable low-wear gliding as much as possible of the shuttle pallet in particular on the roller conveyor, the legs of the load bearing bridges are designed according to the invention in such a way that the longitudinal supports can move relative to one another in the XZ plane wherein the movement is impressed by unevenness of the roller conveyor. Accordingly, the legs are advantageously designed as springy joints, in particular as leaf spring-like joints that enable small movements.
In an advantageous embodiment of the invention, it is provided that the longitudinal supports are comprised of a wear-resistant and bending-resistant semi-finished product, in particular of a tubular section of construction steel or aluminum and particularly preferred of a pipe with circular ring-shaped cross-section with or without flat portion. In this way, the contact of the roller conveyors and the chain conveyors with the longitudinal supports of construction steel or a material with smaller modulus of elasticity can be limited. Because of their material, these longitudinal supports are naturally very wear-resistant and therefore can be used for a long period of time without noticeable wear.
Other longitudinal supports according to the invention are comprised of profiled sections with bending-resistant cross-section that have a larger contact area on the running surface relative to the conveying equipment (roller conveyors etc.) than a pipe with circular ring-shaped cross-section in order to reduce the contact pressure and the stress caused by it. According to the invention, this can be, for example, a pipe that is flattened to form the running surface but is otherwise substantially a circular ring-shaped tube, or a T-shaped profile. Of course, this can also be achieved by any other profiles with bending-resistant cross-section that have at the running surface a larger contact area relative to the conveying equipment. In this way, the contact pressure (Hertzian stress) between longitudinal supports and, for example, the rollers of a roller conveyor is reduced and in this way the thereby occurring stress is reduced.
The Hertzian stress can be further reduced when a material with small modules of elasticity in comparison to steel is employed. This can be, for example, aluminum.
Moreover, by means of the longitudinal supports according to the invention made of a bending-resistant profiled section, even heavily loaded transport pallets can be stored at the storage locations of the high rack storage facility on transverse beams because the longitudinal supports according to the present invention have satisfactory bending stiffness.
In order to ensure that from the load bearing bridges the weight force of the goods supported thereon is introduced safely into the longitudinal supports, legs are formed on each load bearing bridge.
Advantageously, the longitudinal supports are secured only by form fit against falling out in case the shuttle pallet is lifted.
Especially preferred, the longitudinal supports are connected by a snap-on connection or a clip connection with the load bearing area for bridges. When the connection is detachably designed, it is also possible to exchange individual longitudinal supports or even individual load bearing bridges in case of damage so that the economic efficiency of the shuttle pallets according to the invention is further improved.
In a further advantageous embodiment of the invention, it is provided that the load bearing bridges are embodied in a direction orthogonal to the longitudinal supports in a bending resistant way. In a further advantageous embodiment of the invention it is provided that between two load bearing bridges spacers are provided that extend in the direction of the longitudinal supports. In this way it is ensured that the load bearing bridges cannot move relative to one another. As a result of this the dimensions of the shuttle pallets according to the invention will not change even under heavy and frequent loading and a problem-free and disruption-free operation in automated storage systems is ensured.
The spacers and the load bearing bridges can be designed as a monolithic part. As a result of this, for completing the shuttle pallet according to the invention, it is only required to clip the longitudinal supports that are preferably comprised of a tube with circular ring-shaped cross-section onto the load bearing bridges. The load bearing bridges can be made preferably of plastic material, in particular HDPE and/or recycled plastic material. In this way, even complex geometries and a weight-optimized construction can be realized easily.
In order for the shuttle pallet according to the invention to be liftable and transportable by rack servicing devices, forklifts and others, it can be provided that between the longitudinal supports on the bottom side of the shuttle pallet two cutouts extending in longitudinal direction are provided. Advantageously, the spacing of the central axes of the cutouts is between 340 mm and 400 mm and particularly preferred 370 mm.
The height of the cutouts is advantageously greater than 85 mm and the width of the cutouts is greater than 160 mm.
In a further advantageous embodiment of the invention, it is provided that the dimensions of the shuttle pallet, in particular its length and width, match at least the standard dimensions of so-called transport pallets, in particular Euro pallets. In this way, it is firstly possible to place the standardized transport pallets onto the shuttle pallets and the shuttle pallets according to the invention can be inserted into already existing high rack storage facilities. For this purpose it may optionally only be required to enlarge the height of the storage locations somewhat, namely by the height of the shuttle pallet according to the invention.
In order to further improve the force introduction between the transport pallet placed onto the shuttle pallet according to the invention and the longitudinal supports, in a further advantageous embodiment of the invention it is provided that at a topside of the shuttle pallet load bearing points are formed wherein the spacing of the load bearing points relative to one another corresponds to the spacings of the legs of a standardized pallet, in particular a Euro pallet. In this way, the force introduction from the transport pallet into the shuttle pallet is concentrated on defined load bearing points. It is particularly advantageous when the load bearing points are arranged vertically above the legs of the shuttle pallet. In this way, the bending loads resulting from weight forces between the transport pallet and the shuttle pallet are minimized.
In order to reduce wear of the shuttle pallet according to the invention at the topside in the area of the load bearing points, according to a further advantageous embodiment of the invention it can be provided to reinforce the shuttle pallet in the area of the load bearing points, in particular by shells of a wear-resistant material, for example, sheet steel.
Further advantages of advantageous embodiments of the invention will be disclosed in the subsequent drawing, its description, and the claims. All features disclosed in the drawing, its description, and the claims may be important for the invention taken alone or in any combination with one another.
BRIEF DESCRIPTION OF THE DRAWING
It is shown in:
FIG. 1 an isometric illustration from above of a shuttle pallet according to the invention with three load bearing bridges;
FIG. 2 the load bearing bridges according to FIG. 1 without spacers;
FIG. 3 a view of the shuttle pallet according to the invention without and with inserted longitudinal supports;
FIG. 4 a front view of a leg and with clipped-on longitudinal support;
FIG. 5 a front view and a side view of a shuttle pallet according to the invention on a roller conveyor;
FIG. 6 a shuttle pallet with reinforced load bearing points;
FIG. 7 a shuttle pallet with two half-size pallets positioned thereon;
FIG. 8 several stacked shuttle pallets according to the invention; and
FIG. 9 several embodiments of suitable cross-sections of longitudinal supports.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 a first embodiment of a shuttle pallet 1 according to the invention with a total of three load bearing bridges 3 is illustrated in an isometric view. The load bearing bridges 3 are embodied to be bending resistant in the direction of a Y axis and have a plurality of ribs 5 that substantially extend in the direction of the Y axis. The ribs 5 , of which for reasons of clarity not all are provided with reference numerals, ensure the desired bending stiffness in the direction of the Y axis while providing at the same time minimal own weight.
In the area of the load bearing points 7 the ribs 5 are reinforced by transverse ribs 9 . As a whole, there are nine load bearing points 7 that correspond to the load bearing points of conventional transport pallets with respect to arrangement and spacing. When, for example, a Euro pallet (not illustrated) as a typical representative of a transport pallet is positioned on the shuttle pallet according to the invention, the legs of the Euro pallet with their legs are positioned within the area of the load bearing points 7 on the shuttle pallet 1 and the weight force of the transport pallet or of the goods positioned thereon is therefore introduced by means of the load bearing points 7 into the shuttle pallet 1 .
As can be clearly seen in the isometric illustration according to FIG. 1 , an edge 11 of the shuttle pallet 1 is raised somewhat relative to the inner area so that a transport pallet (not illustrated) deposited onto the shuttle pallet is secured laterally and in all directions against sliding.
Below the load bearing points 7 there are legs 13 formed on the load bearing bridges 3 . In accordance with the number of load bearing points 7 there are nine legs 13 provided on the shuttle pallet 1 according to the invention. In this way, it is ensured that the weight forces that are introduced through the load bearing points 7 into the shuttle pallet 1 can be directly transferred downwardly through the legs 13 . In this way, the bending load of the shuttle pallet 1 according to the invention is minimized.
Between the legs 13 that are arranged in the direction of an X axis, corresponding to the longitudinal axis of the shuttle pallet 1 , spacers 15 are provided that ensure that the load bearing bridges 3 are secured relative to one another in the direction of the X axis. In the illustrated embodiment the spacers 15 and the load bearing bridges 3 are embodied as a monolithic part. It is however also possible to connect the spacers 15 detachably to the load bearing bridges 3 so that, when one or several parts ( 3 , 15 ) of the shuttle pallet 1 according to the invention are damaged, they can be exchanged and continued use of the remaining parts is possible.
The load bearing bridges 3 are designed such that they can be easily engaged from below by a fork of a rack servicing device (not illustrated). For this purpose, between the legs 13 of a load bearing bridge 3 cutouts 18 are provided. The rack servicing device engages the shuttle pallet 1 from below with its fork and deposits the loaded shuttle pallet 1 at the storage location.
In FIG. 2 three load bearing bridges 3 without spacers are illustrated. This makes clear that the shuttle pallet 1 according to the invention is torsionally soft so that the shuttle pallet 1 can distort when, for example, it is deposited onto an uneven support or when it glides across a roller conveyor where not all rollers are precisely aligned within one plane. The shuttle pallet 1 is still torsionally soft when provided with the spacers 15 .
Same components are provided with same reference numerals and, accordingly, the explanations provided in connection the other Figures apply as well. For reasons of clarity, not all reference numerals are provided in all Figures.
As can be seen clearly in FIG. 2 , in the legs 13 of the load bearing bridges 3 snap-on connectors 17 is formed with a circular segment-shaped cross-section. These snap-on connectors 17 extend in the direction of the X axis and serve for receiving a longitudinal support (not illustrated) that is preferably comprised of steel pipe with circular cross-section. On the ends of the shuttle pallet 1 these snap-on connectors 17 are closed so that the longitudinal support cannot slide in the direction of the X axis relative to the load bearing bridges 3 .
In FIG. 3 a , the shuttle pallet 1 according to FIG. 1 is illustrated isometrically in a bottom view. This makes clear that these snap-on connectors 17 extend across the entire length of the shuttle pallet 1 and are also formed within the spacers 15 .
In FIG. 3 b , longitudinal supports 19 are inserted into the snap-on connectors 17 . In this way, a form fitting and at the same time detachable connection between the longitudinal supports 19 and the legs 13 as well as the spacers 15 of the shuttle pallet 1 is produced. The longitudinal supports 19 can be made of conventional steel pipe with circular ring-shaped cross-section and are firstly inexpensive and secondly wear resistant and thirdly bending resistant. In this way, the shuttle pallet 1 according to the invention can be loaded with great weights without the shuttle pallet sagging even in case of extended residence time at a storage location.
In FIG. 4 a cross-section of a leg 13 with inserted longitudinal support 19 is illustrated. In this embodiment, the longitudinal support 19 , as in the other embodiments, is embodied as a pipe with circular ring-shaped cross-section and has a longitudinal axis 19 A coinciding with an axis of rotation of the longitudinal support 19 in the snap-on connector 17 . The snap-on connector 17 is comprised of a circular segment section that encompasses more than 180° and is open in the downward direction. In this way, it is possible to insert from below the longitudinal support 19 into the receiving space 17 A of the snap-on connector 17 . Accordingly, for a short period of time the snap-on connector 17 or the leg 13 is briefly widened laterally and elastically returns into its original position as soon as the longitudinal support 19 has assumed the position, illustrated in FIG. 4 , within the leg 13 .
At the bottom the longitudinal support 19 projects somewhat past the leg 13 so that the contact between a roller conveyor or a support onto which the shuttle pallet is placed is exclusively realized through the longitudinal support 19 and not through the leg 13 .
In FIG. 5 a portion of a shuttle pallet according to the invention is illustrated as it glides across a roller conveyor. In the right portion of FIG. 5 , a side view is illustrated. This makes it clear that the longitudinal support 19 is in direct contact with the rollers 21 of the roller conveyor. In this way, the wear on the shuttle pallet is greatly reduced.
Should one of the longitudinal supports 19 as a result of frequent use become worn or damaged to such an extent, it can be exchanged on site without tools and in a very short period of time.
In FIG. 6 a further embodiment of a shuttle pallet according to the invention is illustrated. In this connection, the shuttle pallet is positioned on two beams 23 of a high rack storage facility. The spacing of the beams 23 relative to one another corresponds to the spacing that such beams 23 have in conventional high rack storage facilities and is naturally matched to the length of the Euro pallet or the shuttle pallet.
In the embodiment illustrated in FIG. 6 the load bearing points 7 are provided with reinforcements 25 that prevent wear of the shuttle pallet in this area. These reinforcements can be embodied as shells 25 or sheet metal strips. Here also, for reasons of clarity, not all shells 25 are provided with reference numerals.
Because of the great bending stiffness of the longitudinal supports 19 (not visible in FIG. 6 ) the shuttle pallet according to the invention will not bend even when it is resting on the beams 23 for an extended period of time and loaded with a high weight. In this way, it is possible to even store in a high rack storage facility plastic pallets or nesting pallets of plastic material that, without the additional reinforcement by means of the longitudinal supports 19 according to the invention, over the course of time will bend under the load and therefore cause disruptions in the high rack storage facility.
In FIG. 7 , a shuttle pallet according to the invention is illustrated that is loaded with two transport pallets 27 . 1 and 27 . 2 of half size format. This is possible without problems because the load bearing points 7 have an appropriate size. A line of separation between the two transport pallets of half size is identified by reference numeral 29 .
In FIG. 8 , several stacked shuttle pallets are illustrated that are located at a free spot within the high rack storage facility and whose lowermost one is resting on two beams 23 .
In FIG. 9 a , a longitudinal support 19 is illustrated in cross-section. In this embodiment, the circular ring-shaped cross-section has a flattened portion 31 . In the mounted state, the flattened portion 31 faces downwardly and enlarges in this way the contact surface between longitudinal support 19 and the rollers 21 of a roller conveyor (see FIG. 5 ).
In FIG. 9 b a longitudinal support 19 is shown in cross-section. In this embodiment, the longitudinal support 19 is formed as a T-shaped profiled section 33 . In this way, the contact surface between longitudinal support 19 and the rollers 21 of a roller conveyor is enlarged.
In FIG. 9 c a longitudinal support 19 is shown in cross-section. In this embodiment, a T-shaped profiled section and a circular ring-shaped section are combined. The circular ring-shaped section serves for attachment of the longitudinal support 19 on the load bearing bridges 3 while the T-shaped profiled section 33 forms the contact surface between longitudinal supports 19 and conveying and storage equipment ( 21 , 23 ).
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A shuttle pallet for a high rack storage facility has three longitudinal supports extending parallel to each other. Load bearing bridges orthogonally extend relative to the longitudinal supports. The longitudinal supports and the load bearing bridges are connected to one another in an articulated fashion. The longitudinal supports are made of a wear-resistant and bending-resistant semi-finished product and are form-fittingly and exchangeably connected to the load bearing bridges. The longitudinal supports have in cross-section an area with a circular ring-shaped cross-section. The load bearing bridges have legs. Snap-on-connectors with a circular segment-shaped cross-section are formed on the legs. The longitudinal supports are supported with the circular ring-shaped cross-section rotatably about an axis of rotation and exchangeably in the snap-on connectors, respectively. The axis of rotation extends in a direction of a longitudinal axis of the longitudinal supports.
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TECHNICAL FIELD
This invention relates generally to the recovery of subterranean deposits, and more particularly to a method and system for cleaning a well bore.
BACKGROUND
Subterranean zones that contain valuable deposits frequently include other materials, such as entrained water or solids, that are considered extraneous. Since such materials can interfere with the production of the valuable deposits, it may be desirable or necessary to have some way to remove extraneous materials from the production well bore. One method for handling extraneous, co-produced materials is to form a “sump” or “rat hole.” The sump is a well bore drilled below the production well bore such that extraneous materials are allowed to fall into the sump and to collect therein. Sumps may be drilled vertically or obliquely from an existing well bore.
As materials are collected within the sump, the sump may become nearly or completely filled. In such instances, it is desirable to remove some of the collected material in order to provide sufficient capacity for new material to be collected in the sump. For example, a pump may be lowered into the sump, and water may be pumped to the surface. Such techniques permit the sump to be used to facilitate production after the capacity of the sump would ordinarily have been exhausted. Therefore, it is advantageous to have efficient and versatile methods for removing collected material from a sump. Furthermore, collected materials with a high solid content may present additional challenges for the removal process. For example, the solid phase material may obstruct the flow of collected material through pumps and potentially damage pump mechanisms. In another example, the relatively low liquid content of such collected materials may prove insufficient liquid flow to adequately lubricate and/or cool various types of pumping mechanisms. Consequently, it would be useful to have a technique for extracting collected material that can effectively remove materials with a high solid content as well.
SUMMARY
In a particular implementation, a method for extracting accumulated material from a well bore includes pressurizing gas recovered from the well bore and disposing an extraction string in communication with a sump. The sump is disposed to receive liquid from the well bore. The method further includes sealing the sump and injecting at least a portion of the pressurized gas into the sump such that at least some of the liquid in the sump is driven upward into the extraction string. In another implementation, 1. A system includes a compressor, a sump, a seal, a gas injection string, and an extraction string. The compressor pressurizes gas recovered from a well bore. The sump disposed receives liquid from the well bore. The seal seals the sump so that the sump is substantially airtight when sealed. The gas injection string is coupled to the compressor, and it injects at least a portion of the pressurized gas into the sump. The extraction string disposed within the sump such that at least some of the liquid in the sump is driven upward into the extraction string when the pressurized gas is injected into the sump.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 illustrates a system for extracting liquid from a well bore in accordance with an implementation of the present invention;
FIG. 2 illustrates a cross-sectional view of a working string in the system of FIG. 1 ;
FIG. 3 illustrates a downhole portion of a system for extracting liquid from a well bore; and
FIG. 4 illustrates a method for extracting liquid from a well bore in accordance with another implementation of the present invention.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
FIG. 1 depicts a system 100 for cleaning a well bore 102 . In the depicted implementation, system 100 includes a working string 104 and a compressor 106 with a low pressure line 108 and a high pressure line 110 . System 100 also includes valves 112 A and 112 B coupled to high pressure line 110 that permit pressurized gas to be supplied to other parts of system 100 . Overall, system 100 uses pressurized gas to remove undesired materials from well bore 102 .
In the depicted embodiment, well bore 102 is an articulated well bore extending into a subterranean zone 114 , such as a coal seam, in which there are subterranean deposits of natural gas, such as, for example, methane. An articulated well bore, such as the one depicted in FIG. 1 , includes a first portion that is vertical, a second portion that is oriented within a plane of a subterranean zone, and a curved portion that connects the first and second portions. It should be understood that the described techniques are applicable to other types of well bores, and the articulated well bore is only one example. Well bore 102 may be reinforced using a tubular casing 103 , which is any rigid material affixed (such as, for example, by cementing) within well bore 102 . Although the described implementation describes a gas well, it should be understood that the described methods are also applicable to recover of a variety of materials from a subterranean zone, including natural gas, crude oil, associated solution gas, formation water, injected water, natural gas liquids, and numerous other subterranean minerals and solids. Within subterranean zone 114 , there may be liquids and/or solids that could collect within the horizontal portion of well bore 102 . The accumulation of such liquids and/or solids may interfere with the production of natural gas from well bore 102 . Accordingly, there is a sump 116 drilled below the horizontal portion of well bore 102 , allowing such liquids and solids to drain by gravity or reservoir pressure into sump 116 . Sump 116 may be drilled using any suitable drilling technique, including any of the numerous well-known techniques for directional drilling. Although sump 116 is depicted as being drawn at an angle from well bore 102 , it should be understood that the described techniques are equally applicable to a sump that is drilled vertically.
During gas production, gas produced from well bore 102 travels into a phase separation vessel 130 , where the gas is allowed to flow upward while any entrained liquids and/or solids drop from suspension within phase separation vessel 130 , so that phase separation vessel 130 also acts as a storage vessel 130 for entrained liquids and/or solids. Such entrained liquids and/or solids may include, for example, subterranean water from a coal seam. A floater 132 or other similar level indicator may be used to indicate when the liquid level in storage vessel 130 reaches a predetermined level. When the predetermined level is reached, drain 134 may be opened to drain accumulated liquids and solids from storage vessel 130 . The gas, minus any removed liquids and solids, is then provided to low pressure line 108 of compressor 106 . Compressor 106 pressurizes the gas and sends the pressurized gas out of high pressure line 110 , which carries the pressurized gas to a sales or storage facility.
At the same time, subterranean liquids and/or solids within well bore 102 flow to sump 116 , where they are collected. As liquids and/or solids accumulate within sump 116 , sump 116 may eventually become filled to a level at which it becomes desirable to extract the accumulated material from the sump and produce them at the surface. In previous systems, a pump, such as an electric submersible pump, is placed within sump 116 to pump liquids to the surface through a tube or other conduit. The use of a pump to extract liquids incurs costs to purchase and operate pumps and also introduces technical challenges such as the need for a power and control system for the pump. Additionally, most conventional pumps do not adequately handle high volumes of entrained solids, and they may be damaged if they continue to run in a “pumped off” condition, such as after most of the accumulated material has been extracted Accordingly, it is advantageous to have an alternative technique for extracting liquids and/or solids from sump 116 . Various implementations of the present invention provide such an alternative by using pressurized gas to extract liquid from sump 116 .
In the depicted implementation, system 100 uses packer 118 to act as a seal for an annular space 126 (illustrated in the cross-sectional view of FIG. 2 ) between working string 104 and an interior of sump 116 . Packer 118 may be any suitable device adapted to seal sump 116 in a substantially airtight manner. In the depicted implementation, packer 118 is an inflatable device comprising an expandable material, such as an elastomer or numerous other similar materials, that inflates to seal the annular space between working string 104 and sump 116 . Packer 118 is controlled by a control string 120 . Control string 120 is any suitable apparatus for causing packer 118 to seal and unseal sump 116 . In the depicted implementation, control string 120 comprises tubing that couples high pressure line 110 of compressor 106 to packer 118 through valve 112 A, which valve 112 A also includes a vent 113 to the atmosphere. Valve 112 A may be controlled by any suitable method, such as manual operation, electrically-controlled solenoid actuation, or numerous other methods for opening and closing valves. Valve 112 A may thus be opened, closed, and/or vented to cause packer 118 to be inflated or deflated.
To seal sump 116 , valve 112 A is opened, allowing pressurized gas to flow through control string 120 into packer 118 , thus expanding packer 118 to fill annular space 126 . Once packer 118 is inflated, valve 112 A may be closed to prevent gas from being driven back into high pressure line 110 , such as, for example, by external pressure on packer 118 . To unseal sump 116 , vent 113 of valve 112 A is opened, allowing the pressurized gas in packer 118 to escape into the atmosphere, which in turn deflates packer 118 .
When sump 116 is sealed, working string 104 is used to inject pressurized gas into sump 116 and to recover gas from sump 116 . In the depicted implementation, working string 104 includes a gas injection string 122 and an extraction string 124 , which surrounds gas injection string 122 to define an annular space 126 , as illustrated in the cross-sectional view of working string 104 shown in FIG. 2 . Gas injection string 122 comprises tubing or other suitable conduit that couples sump 116 to high pressure line 110 of compressor 106 through valve 112 B, which may be of a similar type to valve 112 A. By opening valve 112 B while sump 116 is sealed, a flow of pressurized gas through gas injection string 122 raises the pressure in sump 116 , which in turn drives liquid into annular space 126 . As the pressure in sump increases 116 , accumulated material from sump 116 is carried to the surface by extraction string 124 , which may be any suitable form of tubing or conduit for producing liquid and/or solid material to the surface. The produced liquids and/or solids are allowed to flow into storage vessel 130 , where they accumulate along with the products dropped from suspension in the produced gas. As noted above, when the accumulated material exceeds a predetermined level, it may be drained from storage vessel 130 in order to prevent storage vessel 130 from overfilling.
Once the extraction of accumulated material from sump 116 is completed, valve 112 B may be closed to stop the flow of pressurized gas, and packer 118 may be deflated to unseal sump 116 and to permit the pressurized gas in sump 116 to escape. The escaping gas is recovered at the surface along with the rest of the gas produced using well bore 102 . To deflate packer 118 , the gas in packer 118 is vented to the atmosphere through vent 113 of valve 112 A. In an alternative implementation, another valve 112 C may be used to couple control string 120 to a low pressure side of the well system. Such an implementation enables the gas used to inflate packer 118 to be recovered along with the other gas injected into sump 116 . Further, the gas may be introduced into the extraction string 124 , and the sudden entry of gas into extraction string 124 may create a pressure increase that can dislodge debris, such as loose coal or rocks from subterranean zone 114 , that may become caught around the end of working string 104 as liquid enters extraction string 124 .
A variety of techniques may be used to determine when to extract liquid from sump 116 and when sufficient liquid has been drained from sump 116 . In some implementations, the inflation and deflation of packer 118 and the injection of gas is controlled by control timer 136 . Control timer 136 is set to open and close valve 112 A, 112 B, and/or 112 C so that sump 116 is periodically drained. In other implementations, the determination that sufficient liquid has been drained is based on reading a pressure sensor 128 coupled to packer 118 that measures gas and/or liquid pressure. In such an implementation, control string 120 may include an insulated wire or any of numerous other media for carrying signals from pressure sensor 128 to the surface. In an example of operation, pressure sensor 128 may measure the liquid pressure resulting from accumulated liquid in sump 116 . When the pressure exceeds a certain amount, accumulated material is extracted from sump 116 . In another example, pressure sensor 128 may monitor the gas pressure in sealed sump 116 , and once the gas pressure reaches a predetermined level deemed sufficient to indicate that most of the accumulated material in sump 116 has been driven to the surface, sump 116 may be unsealed. Alternatively, a pressure sensor, which may be located on the surface, may be coupled to the gas injection string 122 to monitor the pressure of a constant, low-volume flow of gas. Rising pressure would then indicate an increase in the level of accumulated material. When the pressure reaches a predetermined threshold level, accumulated material is extracted from sump 116 . The implementations described here are merely examples, and it should be understood that numerous other methods for determining when to extract accumulated material from sump 116 and when to unseal sump 116 may be employed.
FIG. 3 illustrates an implementation of a downhole portion of working string 104 . In the depicted implementation, sump 116 has been provided with cavity portions 138 extending transversely to the longitudinal axis of sump 116 . Cavity portions 138 increase the capacity of sump 116 to contain liquid. Pressure sensor 128 is a liquid pressure sensor that is placed to measure the liquid level 140 within sump 116 in order to facilitate the determination of when to extract liquid from sump 116 . In the depicted implementation, extraction string 124 includes a flared, end 142 . End 142 may be flared inward in order to prevent larger debris in sump 116 from being pulled into annular space 126 by the flow of liquid and gas into extraction string 124 . This tends to prevent extraction string 124 from becoming obstructed or clogged by such debris.
FIG. 4 illustrates an example of a method for extracting accumulated material from sump 116 using injection of pressurized gas. At step 402 , valve 112 A coupling packer 118 to high pressure line 110 is opened, inflating packer 118 and sealing sump 116 . Once packer 118 is inflated, valve 112 A to packer 118 may be closed at step 404 . In alternative implementations, valve 112 A may be left open. Valve 112 B coupling gas injection string 122 to high pressure line 110 is opened at step 406 . This causes the pressure in sump to rise, thus driving accumulated liquid and solid material into annular space 126 within extraction string 124 and eventually to the surface. Liquids and/or solids are collected in storage vessel 130 at step 408 . Accumulated material may be drained out of storage vessel 130 to prevent storage vessel 130 from overfilling.
The removal process continues until the drainage of sump 116 has been completed, as shown at decision step 410 . The determination of when the drainage is completed may be made based on elapsed time, measured changes in pressure, or any other suitable method, including any of those described herein. Once the drainage is completed, valve 112 B is closed at step 412 . The gas within packer 118 is then vented at step 414 , thus unsealing sump 116 . The gas from packer 118 may be vented in any suitable manner, including venting the gas to the atmosphere using valve 112 A or venting the gas back into extraction string 124 .
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, the described techniques may be used to extract any manner of liquids and solids from any type of subterranean well drilled using any suitable technique. In another example, the extraction string may be separated from the gas injection string, so that the extraction string does not enclose the gas injection string. Accordingly, other embodiments are within the scope of the following claims.
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A method for extracting accumulated material from a well bore includes pressurizing gas recovered from the well bore and disposing an extraction string in communication with a sump. The sump is disposed to receive liquid from the well bore. The method further includes sealing the sump and injecting at least a portion of the pressurized gas into the sump such that at least some of the liquid in the sump is driven upward into the extraction string.
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FIELD OF THE INVENTION
This invention relates to the discovery of novel pharmaceutical dosage forms of chiral drugs.
BACKGROUND TO THE INVENTION
The separate enantiomers of some chiral drugs have different therapeutic properties, and/or mechanisms of action and yet in some cases it may still be desirable to dose both enantiomers together. However, where the pharmacokinetic properties of the separate enantiomers are different, for instance due to differences in the rates at which they are metabolised, the ratio of the different enantiomers changes with time after initial dosing, which can lead to reduced efficacy of the drug. The actual enantiomeric ratio at any one time may be dependent upon a number of factors, and may be further complicated if different dosage forms provide different enantiomeric ratios. Effects such as these have been observed with the different enantiomers of verapamil, for instance see Longstreth, J.A. Clin. Pharmacol. (1993) 18 (2nd Edition): 315-336 and Gupta et al., Eur. J. Pharm. Biopharm. (1996) 42(1): 74-81.
SUMMARY OF THE INVENTION
According to the present invention, a pharmaceutical dosage form comprises, in one portion thereof, a substantially single (+)-enantiomer of a chiral drug other than verapamil and, in another, separate, portion thereof, a substantially single (-)-enantiomer of the drug, wherein, in use, the different enantiomers are released at different rates from the dosage form.
Where the different enantiomers of the chiral drug are absorbed, metabolised, distributed or secreted by the body at different rates, their rates of release from the dosage form may be arranged such that their initial ratio, whether this is 50:50 or a non-racemic ratio, is maintained, ideally throughout the dosing period. By manipulating the administration of the different enantiomers in this way, presentation of the desired enantiomer to the target organ is optimised, thereby increasing the clinical efficacy of the drug throughout the dosing period.
The present invention may also be beneficial in administering chiral drugs whose individual enantiomers have different efficacies, different modes of action, different selectivities, e.g. to receptors or enzymes, or different toxicities.
The present invention may also be beneficial in administering chiral drugs which have a side effect associated therewith, but where the side effect resides in only one of the drug's two individual enantiomers. In this case, it may be desirable to have a different release rate for the enantiomer causing the side effect, although this will depend upon the nature of the side effect.
Examples of chiral drugs where both enantiomers have a valid pharmacological input, and where a clinical benefit may be realised by controlling the release rates of those enantiomers, include warfarin, tramadol, mianserin, carvedilol, citalopram, dobutamine, aminoglutethimide, alfuzosin, celiprolol, cisapride, disopyramide, fenoldopam, flecainide, hydroxychloroquine, ifosfamide, labetolol, mexiletine, propafenone, tegafur, terazosin, thioctic acid, thiopental and zacopride, and in particular warfarin and tramadol, and most particularly tramadol.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph of concentration of the individual enantiomers of tramadol hydrochloride released with time from the immediate-release tablets prepared in accordance with Example 1.
FIG. 2 is a graph of concentration of the individual enantiomers of tramadol hydrochloride released with time from the controlled-release tablets prepared in accordance with Example 2.
FIG. 3 is a graph of percentage release of the individual enantiomers of tramadol hydrochloride with time from the controlled-release tablets prepared in accordance with Example 2.
FIG. 4 is a graph of concentration of tramadol free base released with time from the bilayered tablets prepared in accordance with Example 3.
DESCRIPTION OF THE INVENTION
The present invention covers any dosage form in which the two enantiomers of a chiral drug are physically separated, or compartmentalised, so as to achieve different release rates of the different enantiomers. Such separation, or compartmentalisation, may be on a macro-scale, for instance with the different enantiomers being incorporated into separate dosage forms for simultaneous or sequential administration, i.e. as a kit, or separation of the different enantiomers may be on a micro-scale, for instance with the different enantiomers being present within the same dosage form and despite their physical separation being intimately mixed, or somewhere intermediate the two.
In the context of this Application, by substantially single enantiomer typically we mean that one enantiomer is in an excess of at least 70% by weight with respect to the other enantiomer, and is preferably in an excess of at least 80%, and more preferably 90%, or higher. Furthermore, by a non-racemic ratio of enantiomers typically we mean that both enantiomers are present, with either the (-)-enantiomer being present in an amount in excess of that of the (+)-enantiomer, or vice versa.
A number of release profiles for the different enantiomers of a chiral drug may be realised by way of the dosage forms of the present invention. For instance, a dosage form may be designed to allow immediate release of one enantiomer and sustained, or controlled, release of the other enantiomer. In this case, by immediate release typically we mean that release of the respective enantiomer occurs substantially immediately or after only a short delay, usually no more than five to ten minutes, after administration of the dosage form, and continues usually over a period of up to one to two hours. By sustained, or controlled, release typically we mean that release of the respective enantiomer is delayed usually for at least one hour and frequently longer, for instance for two or wore hours, after administration of the dosage form. The sustained, or controlled, release may be constant or variable throughout the treatment period.
The dosage forms of the present invention may be designed to release either of the enantiomers faster than the other, or before the other, depending upon the condition to be treated, or the patient type. It may be desirable to maintain a constant ratio of the separate enantiomers at the target tissue over a specified period of time, for instance at least 8 hours a day, preferably at least 12 hours a day, most preferably 24 hours a day. The ratio maintained may be 50:50, or a non-racemic ratio in which either the amount of the (+)-enantiomer is greater than the (-)-enantiomer, or vice versa.
Another option would be to vary the ratio of the two enantiomers throughout the treatment period, or at least for a portion of that period. For instance, the release rate of either or both enantiomers can be arranged to vary, so that either the relative proportion of the (+)-enantiomer or of the (-)-enantiomer increases, or decreases, with time. The latter may be achieved, for instance, by using a number of different release coatings for the respective enantiomer.
As mentioned above, the present invention may have particular application in the administration of tramadol and warfarin. Tramadol is formulated as the racemate for use as a high-potency analgesic with opioid-like properties. The analgesic efficacy and safety of the racemate and the individual enantiomers have been investigated in a randomised, double-blind study with gynaecological patients using intravenous patient-controlled analgesia (see Grond, S, et al. Pain (1995) 62(3):313-320). Although (+)-tramadol appeared to be more potent in producing analgesia, it also produced more nausea and vomiting. Since the racemate has more efficacy than (-)-tramadol and no more side effects than (+)-tramadol, the authors concluded that the racemate had more clinical utility. In another study it was shown that there is complementary and synergistic antinociceptive interaction between the individual enantiomers of tramadol (see Raffa, R. B. et al. J Pharmacol. Exp. Ther. (1993) 267(1): 331-340). The enantiomers have different potencies at opioid receptors, and in inhibiting serotonin re-uptake and noradrenaline re-uptake. It therefore appears that both enantiomers of tramadol contribute to the analgesic effect. Thus, it is possible that controlled administration of the individual enantiomers at different rates, facilitated by the dosage form embodied by the present invention, could result in even more useful analgesia without additional side effects.
A preferred dosage form for administration of tramadol is one in which (-)-tramadol is in immediate-release form and (+)-tramadol is in a sustained-, or controlled-, release form. In this case, the release rate of the (+)-enantiomer could be controlled in such a way to reduce the adverse side effects of nausea and/or dizziness believed to be associated with that enantiomer.
In the case of the anticoagulant drug warfarin, which is currently formulated as the racemate for clinical use, both the (S)-(-)- and (R)-(+)-enantiomers exhibit the desired hypoprothrombinemic activity, with (S)-warfarin being the more potent (see Hyneck, M. et al, Chirality in Drug Design and Synthesis (1990), p. 17-18, ed. C. Brown, Academic Press, London). However, use of warfarin in this form, i.e. as the racemate, is complicated by a delay of a few days before the onset of the desired anticoagulant effect. Thus, once therapy has commenced, careful monitoring is necessary to strike a balance between underdosing and overdosing; overdosing may lead to haemorrhage and may sometimes be fatal. This effect may be attributable to the individual enantiomers of warfarin having different affinities for albumin binding, and their being metabolised by different pathways which in turn will influence relative clearance rates. Thus, administration of separate formulations of the individual enantiomers, or a simple formulation in which the individual enantiomers are separated, may achieve a more controllable treatment regime.
A number of different types of dosage form can be envisaged, for administration by a variety of routes, e.g. oral, rectal, transdermal, nasal, ophthalmic, pulmonary and injectable (subcutaneous or intravenous).
The Applicant's co-pending Application WO 97/33570, describes dosage forms from which the individual enantiomers of verapamil are released at different rates, and any of these may be employed with any of the above drugs.
For instance, one type of dosage form comprises a capsule containing two sets of multiparticulates having different release rates, one set containing the (+)-enantiomer and the other set containing the (-)-enantiomer. The multiparticulates themselves can be made by any of the conventional methods, including extrusion spheronisation, high shear granulation, non-pareil seeds, etc. The rates at which the different enantiomers are released from the multiparticulates can be achieved using any conventional controlled-release mechanism, for instance, matrix (ie. erosion diffusion), coating, or osmotic. Dosage forms of this type are suitable for oral and rectal use.
Another type of dosage form comprises two tablets, i.e. as a combined product (kit), one tablet containing the (+)-enantiomer and the other tablet containing the (-)-enantiomer, the two tablets having different release rates. Again, conventional control-release technology can be used to achieve the desired effect. For example, two tablets having different release coatings or matrices may be used, or two osmotic pump tablets having different pumping rates. The tablets can then be administered in sequence, or they can be filled into a capsule for dosing simultaneously.
Another type of dosage form comprises an osmotic pump tablet comprising two distinct portions, typically two layers, one portion containing and pumping the (+)-enantiomer at one rate, and the other portion containing and pumping the (-)-enantiomer at another rate.
Another type of dosage form comprises a bi-layered tablet, one layer containing the (+)-enantiomer and the other layer containing the (-)-enantiomer, the two layers having different release rates for their respective enantiomers. Again, conventional control-release technology can be used to achieve the desired effect.
One example of a bi-layered tablet may have (-)-tramadol in an outer layer as a starter treatment, leading on to release of (+)-tramadol from the core which would provide maintenance therapy. Another example of a bilayered tablet may have (S)-warfarin in an outer layer as a starter treatment, and (R)-tramadol in a core for maintenance therapy. Different percentages of the individual enantiomers could be used in different tablet preparations so that doses could be titrated for individuals.
Another type of dosage form comprises a compressed coat tablet having a core containing one of the (+)- and (-)-enantiomers and, surrounding the core, a shell containing the other of the (+)- and (-)-enantiomers, the core and shell having different release rates for their respective enantiomers.
Another type of dosage form comprises a patch for placing adjacent a patient's skin, the patch comprising two distinct portions, one portion containing the (+)-enantiomer and the other portion containing the (-)-enantiomer, the two portions having different release rates for their respective enantiomers. Alternatively, two separate patches may be used, i.e. as a combined product (kit), one patch containing the (+)-enantiomer and the other patch containing the (-)-enantiomer, the two patches having different release rates.
Another type of dosage form comprises a polymer implant comprising two distinct portions, one portion containing the (+)-enantiomer and the other portion containing the (-)-enantiomer, the two portions having different release rates for their respective enantiomers. Alternatively, two separate polymer implants may be used, i.e. as a combined product (kit), one implant containing the (+)-enantiomer and the other implant containing the (-)-enantiomer, the two implants having different release rates.
Another type of dosage form comprises an aerosol containing two sets of microparticles having different release rates, one set containing the (+)-enantiomer and the other set containing the (-)-enantiomer. Alternatively, two separate aerosols may be used, one for each enantiomer, i.e. as a combined product (kit), the microparticles of each aerosol having different release rates.
Other types of dosage form may be for administration by injection. With dosage forms of this type, different release rates of the different enantiomers may be achieved by means of, for example, liposomes or microparticulates.
As, in the present invention, the two enantiomers are effectively dosed separately, it is essential that they are provided in a form that is not harmful to the prospective patient. If they are provided in salt form, both salts should preferably be stable and non-hygroscopic.
The dosage forms of the present invention can be used in the treatment of conditions for which the chiral drug is usually administered, particularly in patients disposed to, or who nay be put at risk by exposure to, an adverse side effect.
The present invention is now illustrated by way of the following Examples.
EXAMPLES
In the following, tablets were prepared using a Universal testing Instrument (Instron floor model, Instron Limited, High Wycombe, United Kingdom) at a compression rate of 1 mm/min, using a tabletting pressure of 200 MPa, and an 8 mm flat-faced punch.
The disintegration properties of the tablets were assessed in a disintegration tester (Erweka GmbH, Heusenstamm Germany) according to BP using water at 37° C.±0.2 K. The dissolution profiles of the tablets were evaluated employing the USP XXIII paddle method (Pharmatest, Hamburg, Germany) using 1000 ml distilled water at 37° C.±0.5 K. and a paddle speed of 100 rpm. The dissolved amount of drug, whether (+)- or (-)-tramadol hydrochloride, was measured with on-line UV (Phillips PU 8620, Hamburg, Germany) at a wavelength of 220 nm.
In the accompanying Figures, Figures ▪ represents (+)-tramadol hydrochloride and □× represents (-)-tramadol hydrochloride.
Example 1
Immediate-release tablets were prepared from a powder mixture of 50.0 mg (+)- or (-)-tramadol hydrochloride, 46.5 mg microcrystalline cellulose, 3.0 mg croscarmellose sodium and 0.5 mg magnesium stearate, using a tabletting pressure of 200 MPa. Disintegration was monitored over 30 minutes.
The drug release from the immediate-release tablets is depicted in FIG. 1, with the y-axis showing the concentrations of the individual enantiomers in the dissolution medium. The dissolution pattern observed guarantees a rapid pharmaceutical availability of the drug.
Example 2
Controlled-release tablets were prepared from a powder mixture of 50.00 mg (+)- or (-)-tramadol hydrochloride, 119.15 mg hydroxypropyl methyl cellulose (HPMC) and 0.85 mg magnesium stearate, using a tabletting pressure of 200 MPa. Disintegration was monitored over a period of 7 hours.
The drug release of the controlled-release tablets is depicted in FIG. 2, as a dissolution profile, with the y-axis showing the concentrations of the individual enantiomers in the dissolution medium, and in FIG. 3 as a percentage of drug release. A twelve hour controlled-release was achieved with the present formulation. After 6 hours, the (-)-enantiomer is released slightly faster than the (+)-enantiomer, achieving nearly 100% drug release at 12 hours, whereas only 86% of the (+)-enantiomer was released after 12 hours. Below 6 hours, the drug release profiles of the two enantiomers were very similar.
Example 3
Bi-layered tablets were prepared by pre-compressing the powder mixture of Example 2 at a tabletting pressure of 20 MPa to form a controlled-release layer. The powder mixture of Example 1, containing the opposite enantiomer of tramadol hydrochloride to that used in the controlled-release layer, was then filled on top of the controlled-release layer, and the whole tablet compressed using a tabletting pressure of 200 MPa.
The dissolution profiles of the individual layers of the bi-layered tablets were obtained by chiral HPLC analysis of tramadol free base using a Chiralpak AD Column (eluent 90% heptane, 9.99% isopropanol, 0.01% diethylamine), on which (+)-tramadol had a retention time of 4.5 minutes and (-)-tramadol a retention time of 5.6 minutes, and are depicted in FIG. 4, in which the y-axis shows the concentration of the individual enantiomers in the dissolution medium.
Shorter release profiles from a controlled-release layer may be achieved simply by altering the amount of the excipients used, and in the present case by lowering the amount of HPMC. Furthermore, if increased dosage is required, the tablet diameter may be increased.
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A pharmaceutical dosage form comprises, in one portion thereof, a substantially single (+)-enantiomer of a chiral drug other than verapamil and, in another, separate portion thereof, a substantially single (-)-enantiomer of the drug wherein, in use, the different enantiomers are released at different rates from the dosage form. The dosage form is useful for administration of chiral drugs where both enantiomers have a valid pharmacological input, and where a clinical benefit may be realised by controlling the release rates of those enantiomers. Examples of such drugs include, in particular, tramadol and warfarin.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an exposure apparatus and an exposure method. In particular, the present invention relates to an exposure apparatus and an exposure method for performing projection and exposure on an object to be exposed such as a single crystal substrate for a semiconductor wafer or a glass substrate for a liquid crystal display (LCD).
[0003] 2. Related Background Art
[0004] Up to now, in manufacturing a device (e.g., a semiconductor device, a liquid crystal display device, or a thin film magnetic head) using a photolithographic technique, a projection exposure apparatus has been adopted. The projection exposure apparatus projects and transfers a circuit pattern drawn on a mask or a reticle (in this application, the two terms are used interchangeably) onto a wafer etc., by using a projection optical system.
[0005] As regards the projection exposure apparatus, there is an increasing demand for projection and exposure of the circuit pattern on the reticle to the wafer with a higher resolving power as may keep up with recent miniaturization and high integration scale of an integrated circuit. The smallest possible size (resolution) of the pattern which the projection exposure apparatus transfers is proportional to a wavelength of light used for the exposure but inversely proportional to numerical aperture (NA) of the projection optical system. Accordingly, the shorter the wavelength, the higher the resolution. Thus, in recent years, as the light source, an ultrahigh-pressure mercury lamp (g-line (wavelength: about 436 nm) or i-line (wavelength: about 365 nm)) is replaced by a KrF excimer laser (wavelength: about 248 nm) or an ArF excimer laser (wavelength: about 193 nm) which has a shorter wavelength. Further, an F2 laser (wavelength: about 157 nm) is being put into practical use. In addition, a demand to further enlarge an exposure region is growing.
[0006] To meet such demands, a step-and-scan system exposure apparatus (also called a “scanner”) is gaining popularity over a step-and-repeat system exposure apparatus (also called a “stepper”). The stepper collectively exposes a substantially square exposure region on a wafer after the reduction, whereas the scanner relatively scans the reticle and the wafer at a high speed with the exposure region formed in a rectangular slit-shape to thereby expose a large-area screen with accuracy.
[0007] The scanner effects correction such as alignment of a wafer surface with an optimum exposure position upon exposing a predetermined position of the wafer by measuring a surface position of the wafer at the predetermined position by surface position detection means of an oblique optical system before the predetermined position of the wafer comes in an exposure slit region during the exposure. Thus, it is possible to suppress an influence of a levelness of the wafer.
[0008] As shown in FIG. 16, in particular, plural measurement points (K 1 to K 3 ) are arranged on each of a preceding region 510 and a succeeding region 520 of an exposure slit region 500 in a longitudinal direction (i.e., a direction orthogonal to a scanning direction) of the exposure slit with an intention to measure a tilt as well as a height (focus) of the surface position of the wafer. Here, exposure scanning light is moved from both the preceding region and the succeeding region. Therefore, the measurement points are arranged in the preceding region and the succeeding region of the exposure slit region so that the focus and the tilt of the wafer can be measured prior to the exposure. Various methods of measuring the focus and the tilt have been proposed (see Japanese Patent Application Laid-Open No. H09-45609 (counterpart: US 5750294 B), for example). FIG. 16 is a schematic diagram showing an example of arrangement of the measurement points K 1 to K 3 relative to the exposure region 500 in a conventional case.
[0009] Further, proposed as a method of measuring and correcting a surface position of a wafer in a scanner is a method of arranging plural measurement points in a previously scanning region outside the exposure region and measuring a focus and a tilt in a scanning direction and a non-scanning direction (see Japanese Patent Application Laid-Open No. H06-260391 (counterpart: US 5448332 B), for example). Also proposed is a method of arranging plural measurement points in the exposure region, obtaining measurement information on a focus and a tilt in a scanning direction and a non-scanning direction, and correcting by moving the wafer (see Japanese Patent Application Laid-Open No. H06-283403 (counterpart: US 5448332 B), for example).
[0010] In recent years, a wavelength of the exposure light has been more and more shortened and NA of the projection optical system has further increased, leading to an extremely smaller focal depth. A much higher precision, i.e., focus precision is being needed for aligning the wafer surface to be exposed with a best imaging plane.
[0011] In particular, there are growing needs for the precise measurement on the tilt of the wafer surface in the scanning direction (transverse direction of the exposure region) and the accurate correction of the tilt. The need for the enhancement of a property of following the focus in the exposure area of the wafer that has too rough (uneven) surface is also growing.
[0012] However, even if the surface position of the wafer is measured in the exposure region and corrected by moving the wafer, there is a defect in that on account of being subjected to scanning exposure, the wafer is corrected and moved too late for alignment of the wafer surface to be exposed with the best imaging plane.
[0013] Also, a method of arranging plural measurement points in a scanning direction and a non-scanning direction in the exposure region and obtaining information on tilt of the wafer in the scanning direction based on chronological information obtained through scanning of the wafer encounters a problem that measurements includes an asynchronous error to lower measurement precision, for example, making it impossible to align the wafer surface to be exposed with the best imaging plane.
SUMMARY OF THE INVENTION
[0014] In view of the above problems, the present invention has an exemplary object to provide an exposure apparatus and an exposure method, and a device manufacturing method, with which a wafer surface to be exposed can be aligned with a best imaging plane with respect to a reduced focal depth and a high resolution can be attained.
[0015] In order to attain the above-mentioned object, according to one aspect of the present invention, an exposure apparatus for exposing a pattern formed on a reticle to an object to be exposed includes:
[0016] detecting means for measuring a position of the object to be exposed at a plurality of first measurement positions that meet a predetermined relative positional relationship in an exposure region of the object to be exposed to which the pattern is exposed and for measuring a position of the object to be exposed at a plurality of second measurement positions that meet the predetermined relative positional relationship in regions outside the exposure region; and
[0017] control means for controlling at least one of a position, a height, and a tilt of the object to be exposed based on information on the position of the object to be exposed which is measured by the detecting means.
[0018] Other objects and features of the present invention will be apparent upon reading the following explanation of preferred embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0020] [0020]FIG. 1 is a schematic structural diagram showing an exemplary form of an exposure apparatus according to an aspect of the present invention;
[0021] [0021]FIG. 2 is a schematic diagram showing an example of an arrangement of five measurement points relative to an exposure region;
[0022] [0022]FIG. 3 is a schematic diagram showing an example of arrangement of three measurement points relative to an exposure region;
[0023] [0023]FIG. 4 is a schematic perspective view showing an exposure region and measurement positions of a focus and a tilt of a wafer;
[0024] [0024]FIG. 5 is a schematic perspective view showing a state in which the wafer is moved to an exposure position based on information on the focus and the tilt of the wafer measured at the measurement positions;
[0025] [0025]FIG. 6 is a schematic sectional view showing the wafer in a non-scanning direction in the case where measurement points of the measurement positions do not match confirmative measurement points of the exposure position;
[0026] [0026]FIG. 7 is a schematic diagram showing an example of arrangement of measurement points relative to the exposure region;
[0027] [0027]FIG. 8 is an optical schematic diagram showing a focus and tilt measuring system in the exposure apparatus of FIG. 1;
[0028] [0028]FIG. 9 is a schematic plan view showing a wafer in the case where slit-shaped marks to be projected to the measurement positions and the confirmative measurement positions are aligned in the same direction;
[0029] [0029]FIG. 10 is a schematic diagram showing deficit of the measurement points in the case where the slit-shaped marks to be projected to the wafer are aligned in the same direction;
[0030] [0030]FIG. 11 is a schematic plan view showing a wafer in the case where arrangement is conducted such that the slit-shaped marks to be projected to the measurement points and the confirmative measurement points are obliquely formed and the slits have pitch directions oriented toward a center measurement point;
[0031] [0031]FIG. 12 is a schematic diagram showing deficit of the measurement points in the case where arrangement is conducted such that the slit-shaped marks to be projected to the measurement points and the confirmative measurement points are obliquely formed and the slits have pitch directions oriented toward the center measurement point;
[0032] [0032]FIGS. 13A, 13B, and 13 C show schematic arrangement of a measuring optical system for attaining the arrangement of the measurement points of FIG. 8;
[0033] [0033]FIG. 14 is a flowchart illustrating how to manufacture a device (semiconductor chip such as IC or LSI, an LCD, a CCD, etc.);
[0034] [0034]FIG. 15 is a flowchart showing a wafer process in Step 4 of FIG. 14 in detail; and
[0035] [0035]FIG. 16 is a schematic diagram showing an example of arrangement of measurement points relative to an exposure region in a conventional case.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] Hereinafter, an exposure apparatus according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to the embodiment but allows any alternative replacement of structural members within a range where an object of the present invention is attained. FIG. 1 is a schematic structural diagram showing an exemplary form of an exposure apparatus 100 according to an aspect of the present invention.
[0037] As shown in FIG. 1, the exposure apparatus 100 includes: a light source 110 ; an illumination optical system 120 ; a reticle stage 135 for holding a reticle 130 ; a projection optical system 140 ; a wafer stage 155 for holding a wafer 150 ; a detection system 160 ; and a control unit 170 . The exposure apparatus 100 is a projection exposure apparatus of, for example, a step-and-repeat system or a step-and-scan system, and exposes a circuit pattern formed on a reticle to a wafer. Such an exposure apparatus is suitably used in a lithographic process which requires precision on the order of submicron meter or quatermicron meter or smaller. Hereinbelow, this embodiment will be described taking as an example the step-and-scan system exposure apparatus (scanner).
[0038] Light emitted from the light source 110 such as an excimer laser passes through the illumination optical system 120 where the light is shaped into an exposure beam having a given shape optimum for the exposure to thereby illuminate a pattern formed on the reticle 130 . The pattern on the reticle 130 includes an IC circuit pattern as an exposure target. The light (beam) outgoing from such a pattern is transmitted through the projection optical system 140 and then focused into an image near the wafer 150 surface corresponding to an imaging plane.
[0039] The reticle 130 is mounted on the reticle stage 135 movable within a plane orthogonal to an optical axis of the projection optical system 140 and in a direction of the optical axis.
[0040] The wafer 150 is mounted on the wafer stage 155 movable within a plane orthogonal to the optical axis of the projection optical system 140 and in the optical axis direction and capable of tilt correction.
[0041] The reticle stage 135 and the wafer stage 155 are relatively scanned at a speed proportional to an exposure factor to conduct the exposure of a shot region of the reticle 130 . After the completion of the one-shot exposure, the wafer stage 150 is stepped to a next shot and scanning exposure is performed in a direction opposite to the previous scanning direction to thereby exposure the next shot region. Repeating this operation enables the shot exposure for the entire wafer 150 .
[0042] During the one-shot scanning exposure, surface position information of the wafer 150 surface is obtained by the detection system 160 for measuring a focus and a tilt. Further, a displacement from the exposure image plane is calculated based on the information. Thus, the wafer stage 155 is driven in a direction of the focus (height) and tilt to thereby effect alignment in correspondence with a shape in a height direction of the wafer 150 substantially on the exposure slit basis.
[0043] The detection system 160 adopts an optical height-measuring system. Used is a method of causing the beam to enter the wafer 150 surface with a large angle thereto (small incident angle) and detecting the displacement of an image formed by reflection light from the wafer 150 with a position detection device such as a CCD camera. The beams are allowed to enter the wafer 150 at plural measurement target points. The respective beams are guided to individual sensors to obtain information on measurements of heights at the different points, thereby calculating a tilt of the surface to be exposed.
[0044] As shown in FIGS. 2 and 3, plural measurement points (K 1 to K 5 ) are arranged to form a plane in a preceding region 510 and a succeeding region 520 relative to an exposure region (i.e., exposure slit position) 500 . Before the exposure slit that is being subjected to scanning exposure reaches the exposure region 500 , the information on the focus and the tilt of the wafer 150 , in particular, information on the tilt in the scanning direction can be obtained through the measurement simultaneously. FIGS. 2 and 3 are schematic diagrams each showing an example of arrangement of the measurement points K 1 to K 5 relative to the exposure region 500 . FIG. 2 shows a case where the five measurement points K 1 to K 5 are arranged, whereas FIG. 3 shows a case where the three measurement points K 1 to K 3 are arranged.
[0045] The above three or five measurement points are not limited to those values but may be arbitrary number of measurement points insofar as the number is 3 or more. The three or more measurement points are preferably arranged not to be aligned. In other words, when the three points are selected from the three or more measurement points, the three points preferably form a triangle as viewed from the direction perpendicular to the wafer.
[0046] With reference to FIG. 2, the five measurement points K 1 to K 5 are arranged in the preceding region 510 relative to the exposure region 500 such that the projection is performed thereon. Before the exposure slit reaches the exposure region 500 , the information on the focus and the tilt just before the exposure is obtained with high precision, enabling the correction of the exposure position by moving the wafer. Similarly, to cope with the scanning exposure in the opposite direction, the five measurement points K 1 to K 5 are arranged in the succeeding region 520 such that the projection is performed thereon as well.
[0047] Further, to confirm the focus and the tilt of the wafer 150 during the exposure, the same number of (i.e., five) confirmative measurement points CK 1 to CK 5 are arranged in the exposure region 500 at almost the same positions as the preceding region 510 and the succeeding region 520 . That is, arranging the confirmative measurement points CK 1 to CK 5 enables confirmation of a correction drive amount of the wafer 150 according to the measurements obtained in the preceding region 510 and succeeding region 520 relative to the exposure region 500 .
[0048] In this embodiment, the rectangular exposure region is exemplified. However, the present invention is also applicable to an arc-shaped slit. In such a case, the three measurement points are preferably arranged in an arc shape. For example, in the case of arranging the five measurement points, the five points may be arranged suitably for the control of circumscribed rectangle of the arc-shaped exposure region.
[0049] This arrangement is an improvement on a method of arranging the measurement points in line in a non-scanning direction, measuring the focus chronologically, and obtaining the tilt information in the scanning direction, with which chronological errors are caused to hinder the measurement with high precision.
[0050] Here, the surface position correction through the measurement of the focus and the tilt during the scanning exposure is outlined. As shown in FIG. 4, the measurement is performed on the focus of the surface position of the wafer 150 , a tilt (referred to as “tilt X”) in a longitudinal direction of the exposure slit region (direction perpendicular to a scanning direction SD) and in addition, a tilt (referred to as “tilt Y”) in a transverse direction of the exposure slit (the scanning direction SD) at a measurement position FP including the plural measurement points arranged to form a plane ahead of the exposure slit, before the wafer 150 having an uneven surface shape in the scanning direction SD reaches an exposure position EP. Based on the information on the measurements, the control unit 170 drives the wafer stage 155 and corrects the surface position of the wafer 150 to the exposure position EP by moving the wafer as shown in FIG. 5. With reference to FIG. 5, by the time when the region measured prior to the exposure reaches the exposure slit, the correction is completed. The exposure is conducted at the exposure slit. Note that the control unit 170 is communicable with the detection system 160 . The correction drive amount of the wafer 150 determined on the basis of measurements of the focus and the tilt at the measurement points K 1 to K 5 in the measurement position FP is compared with the measurements of the focus and the tilt at the confirmative measurement points CK 1 to CK 5 in the exposure position EP for the confirmation. The control unit 170 , if there is a difference between the measurements of the focus and the tilt at the confirmative measurement points CK 1 to CK 5 in the exposure position EP and the correction drive amount, feeds back the difference to a next drive amount as a correction value. FIG. 4 is a schematic perspective view showing the exposure position EP and the measurement position FP for measuring the focus and the tilt, on the wafer 150 . FIG. 5 is a schematic perspective view showing a state where the wafer 150 is moved to the exposure position EP based on the information on the focus and the tilt of the wafer 150 obtained at the measurement position FP.
[0051] Further, the confirmative measurement points CK 1 to CK 5 at the exposure position EP are arranged for obtaining the information on the focus and the tilt of the wafer 150 at almost the same position as the measurement position FP preceding the exposure position EP. Accordingly, it is possible to confirm the correction drive amount of the wafer 150 free of the influence of the locally developed surface unevennesses of the wafer 150 .
[0052] Here, a description is made of an influence of the locally developed surface unevennesses of the wafer 150 in such a case that the arrangement of the measurement points for measuring the surface position of the wafer 150 differs between the measurement position FP and the exposure position EP. FIG. 6 is a schematic sectional diagram of the wafer 150 in the non-scanning direction in the case where the arrangement of the measurement points K 1 to K 3 in the measurement position FP is different from that of the confirmative measurement points CK 1 and CK 2 in the exposure position EP.
[0053] With reference to FIG. 6, the wafer 150 surface has the locally developed unevennesses. Then, the measurement points K 1 to K 3 in the measurement position FP do not match the confirmative measurement points CK 1 and CK 2 in the exposure position EP. In other words, the focus and the tilt of the wafer 150 are measured in the measurement position FP and the exposure position EP at different points. As a result, an error Δd is caused between a previous measurement plane PMP defined from the measurements at the measurement points K 1 to K 3 and an exposure position plane CKP defined from the measurements at the confirmative measurement points CK 1 and CK 2 .
[0054] The confirmative measurement points CK 1 and CK 2 in the exposure position EP are arranged for confirming the correction amount calculated from the measurements at the measurement points K 1 to K 3 in the measurement position FP. Thus, it is important to yield an exact correction amount of the wafer 150 . This is because in the exposure position EP, the focus and the tilt of the wafer 150 are measured at the confirmative measurement points CK 1 and CK 2 different from the measurement points K 1 to K 3 in the measurement position FP, so that the error Ad is added in the result by the locally developed unevennesses of the wafer 150 at the exposure position EP. If the error Δd is caused in the measurements of the focus and the tilt at the confirmative measurement points CK 1 and CK 2 , the correction value including the error Δd is added to the next correction drive amount. Therefore, the wafer 150 cannot be aligned with the best imaging plane BFP. In this embodiment, as shown in FIGS. 2 and 3, the confirmative measurement points CK 1 to CK 5 within the exposure region 500 are arranged at almost the same positions as the measurement points K 1 to K 5 in the preceding region 510 and the succeeding region 520 relative to the exposure region 500 , enabling the correction of the surface position of the wafer 150 by moving the wafer (and confirmation of the correction drive amount) with high precision.
[0055] In particular, as shown in FIG. 7, the arrangement is preferably performed such that, if the surface of the wafer 150 is too rough (uneven), the distance between the measurement point K 2 and the measurement point K 4 differs from that between the measurement point K 1 , and the measurement point K 3 and the measurement point K 5 . With this arrangement, even though the measurements of the focus and the tilt of the wafer 150 at the measurement points K 1 to K 5 somewhat fail owing to the uneven surface of the wafer 150 , the rest of the measurement points K 1 to K 5 are arranged to form a plane, enabling the measurement of the tilt in the scanning direction with high precision. FIG. 7 is a schematic diagram showing an example of the arrangement of the measurement points K 1 to K 5 relative to the exposure region 500 .
[0056] Also, the plural slit-shaped beams are projected to the measurement points where the focus and the tilt of the wafer 150 are measured and received by a position detection device such as a CCD, by which the measurements can be obtained and controlled for each slit. As a result, the deficit of the measurement points around the wafer 150 can be minimized and the measurement precision around the wafer 150 can be enhanced.
[0057] [0057]FIG. 8 is an enlarged view of a region A of FIG. 1. In addition, FIG. 8 is an optical schematic diagram showing a measuring system for the focus and the tilt in the exposure apparatus 100 . Note that FIG. 8 merely shows a state where the five measurement points K 1 to K 5 are arranged in the measurement region for the focus and the tilt (e.g., in the preceding region 510 ) for convenience of explanation. In particular, in this embodiment, shown in FIG. 8 are shapes of marks M 1 to M 5 that are projected in such a way that the distance between the measurement point K 2 and the measurement point K 4 differs from the distance between the measurement point K 1 , and the measurement point K 3 and the measurement point K 5 .
[0058] The focus and tilt measuring optical system is arranged such that plural light beams are incident from a direction substantially orthogonal to the scanning direction. The marks M 1 to M 5 to be projected to the measurement points K 1 to K 5 are each projected after being rotated by a predetermined amount in a cross section of the optical axis of the focus and tilt measuring optical system. As a result, the measurement slits are obliquely formed on the wafer 150 and in addition, the slits have pitch directions oriented toward the center measurement point. This makes it possible to minimize the deficit of the measurement points K 1 to K 5 around the wafer 150 and to improve the measurement precision around the wafer 150 .
[0059] As shown in FIG. 9, if the marks M 1 to M 5 to be projected to the measurement points K 1 to K 5 of the wafer 150 and the confirmative measurement points CK 1 to CK 5 thereof are oriented toward the same direction, as shown in FIG. 10, the deficit condition of the measurement points may vary on the wafer 150 since the wafer 150 has a circular shape. With reference to FIG. 10, all the three slits of the mark M 4 are on an edge 150 a of the wafer 150 at a time. As a result, the mark M 4 is of no use in measuring the focus and the tilt of the wafer 150 . FIG. 9 is a schematic plan view showing the wafer 150 in the case where the marks M 1 to M 5 to be projected to the measurement points K 1 to K 5 of the wafer 150 and the confirmative measurement points CK 1 to CK 5 thereof are oriented toward the same direction. FIG. 10 is a schematic diagram showing a deficit of the measurement points in the case where the slit-shaped marks M 1 to M 5 to be projected to the wafer 150 are oriented toward the same direction.
[0060] On the other hand, as shown in FIG. 11, the arrangement is conducted such that the slit-shaped marks M 1 to M 5 to be projected to the measurement points K 1 to K 5 of the wafer 150 and the confirmative measurement points CK 1 to CK 5 thereof are obliquely formed on the wafer 150 and in addition, the slits have pitch directions oriented toward the center measurement point. With such an arrangement, as shown in FIG. 12, the outermost slit of the mark M 4 is solely on the edge 150 a of the wafer 150 and is thus of no use in measuring the focus and the tilt of the wafer 150 . As a result, the rest of the slits (two slits) of the mark M 4 can be used to measure the focus and the tilt of the wafer 150 . FIG. 11 is a schematic plan view showing the wafer 150 in the case where the slit-shaped marks M 1 to M 5 to be projected to the measurement points K 1 to K 5 of the wafer 150 and the confirmative measurement points CK 1 to CK 5 thereof are obliquely formed on the wafer 150 and in addition, the slits have pitch directions oriented toward the center measurement point. FIG. 12 is a schematic diagram showing a deficit condition of the measurement points in the case where the slit-shaped marks M 1 to M 5 to be projected to the measurement points K 1 to K 5 and the confirmative measurement points CK 1 to CK 5 are obliquely formed on the wafer 150 and in addition, the slits have pitch directions oriented toward the center measurement point.
[0061] [0061]FIG. 13A schematically shows an arrangement of the measuring optical system for attaining the arrangement of the measurement points shown in FIG. 8. Five illumination lenses 161 transmit the light supplied from a light source (not shown) therethrough to illuminate the focus measuring slit-shaped marks formed on a focus measuring projection pattern mask 162 . The light source is desirably a halogen lamp or an LED with a somewhat wide wavelength range so as not to expose a photosensitive resist on the wafer 150 and so as to suppress an influence of resist thin-film interference.
[0062] As shown in FIG. 13C, the focus measuring projection pattern mask 162 has slit-shaped marks whose number corresponding to the number of the plural measurement points. The beams obtained by illuminating the plural measurement marks undergo optical-path synthesis with an optical-path combining prism 163 . Thus, the combined beam is projected obliquely on the wafer 150 by a focus mark projection optical system 164 .
[0063] The beam reflected on the wafer 150 surface forms an intermediate imaging point in an optical-path dividing prism 166 using a focus light-receiving optical system 165 . After the beam undergoes optical-path division for each measurement point through the optical-path dividing prism 166 . After that, the divided beams are guided to position detection devices 168 for each measurement point by an enlargement detecting optical system 167 arranged for each measurement point with intent to improve a measurement resolving power. In this embodiment, used as the position detection device 168 is a one-dimensional CCD with the measurement direction set to the direction in which the devices are arranged.
[0064] In the perspective view of FIG. 13B, the relationship among the measuring marks, the position detection devices 168 , and the enlargement detection optical system 167 is shown as viewed from the position detection device 168 in the optical axis direction. The position detection devices 168 for each measurement point are arranged in a direction orthogonal to the slit-shaped marks.
[0065] As the position detection device 168 , the one-dimensional CCD is adopted in this embodiment but a two-dimensional CCD may be disposed. Alternatively, a reference slit plate may be formed on an imaging plane of a light-receiving device to detect, by scanning with the beam before the reference slit plate, an amount of light transmitted through the reference slit plate.
[0066] The description has been made based on a structural example in which the five measurement points are arranged in each surface position measurement region. However, the same can apply to the arrangement of the three measurement points for each measurement region.
[0067] According to the exposure apparatus and the exposure method as set forth, the wafer surface to be exposed can be aligned with the best imaging plane with respect to a focal depth to be reduced, making it possible to attain the high resolution.
[0068] Next, with reference to FIGS. 14 and 15, an embodiment of a device manufacturing method using the aforementioned exposure apparatus 100 will be described. FIG. 14 is a flowchart for illustrating how to manufacture the device (e.g., semiconductor chip such as IC or LSI, an LCD, or a CCD). Here, the description is given to an example of a manufacturing process for the semiconductor chip. In Step 1 (circuit design), the device is designed. In Step 2 (mask making), a mask having the designed circuit pattern formed thereon is prepared. In Step 3 (wafer fabrication), a wafer is formed of silicon or other such materials. In Step 4 (wafer processing) called an upstream process, an actual circuit is formed on the wafer by a lithographic technique using the mask and the wafer. In Step 5 (packaging) called a downstream process, a semiconductor chip is obtained from the wafer produced in Step 4 . Step 5 includes an assembly step (dicing and bonding), a packaging step (chip encapsulation), or other such steps. In Step 6 (testing), tests such as an operation confirming test and a durability test are performed on the semiconductor device prepared in Step 5 . Through those steps, the semiconductor device is completed, followed by shipment (in Step 7 ).
[0069] [0069]FIG. 15 is a flowchart showing the wafer process in Step 4 of FIG. 14 in detail. In Step 11 (oxidation), the wafer surface is oxidized. In step 12 (CVD), an insulating film is formed on the wafer surface. In Step 13 (electrode formation), the electrode is formed through deposition etc., on the wafer. In Step 14 (ion implantation), ions are implanted into the wafer. In Step 15 (resist processing), a photosensitive agent is applied to the wafer. In Step 16 (exposure), the circuit pattern of the mask is exposed to the wafer by the exposure apparatus 100 . In Step 17 (developing), the exposed wafer is developed. In Step 18 (etching), portions other than a developed resist image are etched away. In Step 19 (resist stripping), the unnecessary resist after the etching is removed. By repeating those steps, the circuit patterns are multiply formed on the wafer. According to the device manufacturing method of this embodiment, the device with a higher grade than the related arts can be manufactured. As set forth, the device manufacturing method using the exposure apparatus 100 , and the resultant device are provided as another aspect of the present invention.
[0070] The entire disclosure of Japanese Patent Application Laid-Open No. 2003-070196 filed on Mar. 14, 2003 including claims, specification, drawings and abstract are incorporated herein by reference in its entirety.
[0071] As many apparently widely different embodiments of the present invention can be made without departing from the spirit and scope thereof, it is to be understood that the invention is not limited to the specific embodiments thereof except as defined in the claims.
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To provide an exposure apparatus with which a wafer surface to be exposed can be aligned with a best imaging plane with respect to a reduced focal depth and a high resolution can be attained. The exposure apparatus for exposing a pattern formed on a reticle to an object to be exposed includes: a detecting unit for measuring a position of the object to be exposed at a plurality of first measurement positions that meet a predetermined relative positional relationship in an exposure region of the object to be exposed to which the pattern is exposed and for measuring a position of the object to be exposed at a plurality of second measurement positions that meet the predetermined relative positional relationship in regions outside the exposure region; and a control unit for controlling at least one of a position, a height, and a tilt of the object to be exposed based on information on the position of the object to be exposed which is measured by the detecting unit.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/986,414, filed on Nov. 8, 2007. The disclosure of the above application is incorporated herein by reference in its entirety.
FIELD
The present disclosure relates to hybrid vehicles, and more particularly to shutdown path diagnostics for a motor of a hybrid vehicle.
BACKGROUND
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
Referring now to FIG. 1 , an exemplary electric hybrid vehicle 10 is shown. The electric hybrid vehicle 10 includes an engine assembly 12 , a hybrid power assembly 14 , a transmission 16 , a drive axle 18 , and a control module 20 . The engine assembly 12 includes an internal combustion engine 22 that is in communication with an intake system 24 , a fuel system 26 , and an ignition system 28 .
The intake system 24 includes an intake manifold 30 , a throttle 32 , and an electronic throttle control (ETC) 34 . The ETC 34 controls the throttle 32 to control airflow into the engine 22 . The fuel system 26 includes fuel injectors (not shown) to control a fuel flow into the engine 22 . The ignition system 28 ignites an air/fuel mixture provided to the engine 22 by the intake system 24 and the fuel system 26 .
The engine 22 is coupled to the transmission 16 via a coupling device 44 . The coupling device 44 may include one or more clutches and/or a torque converter. The engine 22 generates torque to drive the transmission 16 and propel the electric hybrid vehicle 10 . The transmission 16 transfers power from the engine 22 to an output shaft 46 , which rotatably drives the drive axle 18 .
The hybrid power assembly 14 includes one or more motor generator units. For example only, as shown in FIG. 1 , the hybrid power assembly 14 includes two motor generator units: a first motor generator unit (MGU) 38 and a second MGU 40 . The hybrid power assembly 14 also includes a power control device 41 and a rechargeable battery 42 .
The first and second MGUs 38 and 40 operate independently and at any given time may each operate as either a motor or a generator. An MGU operating as a motor supplies power (e.g., torque), all or a portion of which may be used to drive the output shaft 46 . An MGU operating as a generator converts mechanical power into electrical power.
For example only, the first MGU 38 may generate electrical power based on the output of the engine 22 , and the second MGU 40 may generate electrical power based on the output shaft 46 . Electrical power generated by one of the MGUs 38 and 40 may be used, for example, to power the other of the MGUs 38 and 40 , to recharge the battery 42 , and/or to power electrical components. While the MGUs 38 and 40 are shown as being located within the transmission 16 , the MGUs 38 and 40 may be located in any suitable location.
The control module 20 is in communication with the fuel system 26 , the ignition system 28 , the ETC 34 , the MGUs 38 and 40 , the power control device 41 , and the battery 42 . The control module 20 is also in communication with an engine speed sensor 48 that measures an engine speed. For example, the engine speed may be based on the rotation of the crankshaft. The engine speed sensor 48 may be located within the engine 22 or at any suitable location, such as near the crankshaft.
The control module 20 controls operation of the engine 22 and the MGUs 38 and 40 . The control module 20 also selectively controls recharging of the battery 42 . The control module 20 controls recharging of the battery 42 and the operation of the MGUs 38 and 40 via the power control device 41 . The power control device 41 controls power flow between the battery 42 and the MGUs 38 and 40 . For example only, the power control device 41 may be an inverter and/or an IGBT (insulated gate bipolar transistor).
The control module 20 may include multiple processors for controlling respective operations of the electric hybrid vehicle 10 . For example, the control module 20 may include a first processor for determining desired torque for the engine 22 and the MGUs 38 and 40 and a second processor for controlling torque of each of the MGUs 38 and 40 .
SUMMARY
A diagnostic system for a hybrid vehicle comprises a motor control module and a fault diagnostic module. The motor control module controls torque output of an electric motor having a predetermined number of phases. The fault diagnostic module determines a position of a rotor of the electric motor, aligns the rotor with a phase angle of one of the phases, selectively diagnoses a fault based on a current of at least one of the phases, and selectively disables the electric motor based on the diagnosis.
In further features, the fault diagnostic module determines a positive phase angle and a negative phase angle for each of the phases and aligns the rotor with one of the positive and negative phase angles of one of the phases.
In still further features, the fault diagnostic module determines a nearest phase angle based on the position of the rotor and the positive and negative phase angles and aligns the rotor with the nearest phase angle.
In other features, the fault diagnostic module aligns the rotor with the phase angle by commanding application of an aligning current to the electric motor based on the position of the rotor and the phase angle.
In further features, the fault diagnostic module determines when the rotor is aligned with the phase angle based on a comparison of a measured current through one of the phases and a respective current threshold for the one of the phases.
In other features, the current is a normalized current determined for one of the phases.
In further features, the fault diagnostic module determines the normalized current based on a first current of the one of the phases measured when the rotor is aligned with the phase angle and a second current of the one of the phases measured over a period after the rotor is aligned with the phase angle.
In still further features, the fault diagnostic module diagnoses the fault when the normalized current is greater than a first current threshold.
In other features, the fault diagnostic module diagnoses the fault when the normalized current is at least one of less than a second current threshold and greater than a third current threshold, wherein the third current threshold is greater than the second current threshold.
In further features, the fault diagnostic module disables operation of the electric motor when the fault is diagnosed.
A method for a hybrid vehicle comprises: controlling torque output of an electric motor having a predetermined number of phases; determining a position of a rotor of the electric motor; aligning the rotor with a phase angle of one of the phases; selectively diagnosing a fault based on a current of at least one of the phases; and selectively disabling the electric motor based on the diagnosis.
In further features, the method further comprises determining a positive phase angle and a negative phase angle for each of the phases of the electric motor, wherein the aligning the rotor comprises aligning the rotor with one of the positive and negative phase angles of one of the phases.
In still further features, the method further comprises determining a nearest phase angle based on the position of the rotor and the positive and negative phase angles, wherein the aligning the rotor comprises aligning the rotor with the nearest phase angle.
In other features, the aligning the rotor with the phase angle comprises commanding application of an aligning current to the electric motor based on the position of the rotor and the phase angle.
In further features, the method further comprises determining when the rotor is aligned with the phase angle based on a comparison of a measured current through one of the phases and a respective current threshold for the one of the phases.
In other features, the current is a normalized current determined for one of the phases.
In further features, the method further comprises determining the normalized current based on a first current of the one of the phases measured when the rotor is aligned with the phase angle and a second current of the one of the phases measured over a period after the rotor is aligned with the phase angle.
In still further features, the selectively diagnosing the fault comprises diagnosing the fault when the normalized current is greater than a first current threshold.
In other features, the selectively diagnosing the fault comprises diagnosing the fault when the normalized current is at least one of less than a second current threshold and greater than a third current threshold, wherein the third current threshold is greater than the second current threshold.
In still other features, the selectively disabling comprises disabling operation of the electric motor when the fault is diagnosed.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a functional block diagram of an exemplary electric hybrid vehicle control system;
FIG. 2 is a functional block diagram of an exemplary control module that includes a hybrid control processor and a motor control processor according to the present disclosure;
FIG. 3 is an exemplary flow diagram illustrating steps of a method for verifying a first shutdown test according to the present disclosure; and
FIG. 4 is an exemplary flow diagram illustrating steps of a method for verifying a second shutdown test according to the present disclosure.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is in no way intended to limit the disclosure, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical or. It should be understood that steps within a method may be executed in different order without altering the principles of the present disclosure.
As used herein, the term module refers to an Application Specific Integrated Circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.
Referring now to FIG. 2 , a functional block diagram of an exemplary control module 100 of an electric hybrid vehicle according to the present disclosure is presented. The control module 100 includes a drive diagnostic module 102 , a hybrid control processor (HCP) 104 , and a motor control processor (MCP) 106 . The drive diagnostic module 102 receives various inputs including, but not limited to, engine speed, motor speed, and motor torque.
For example, the drive diagnostic module 102 receives the engine speed from the engine speed sensor 48 . The drive diagnostic module 102 also receives a motor speed measured by a motor speed sensor 107 and a motor torque (T mot ) measured by a motor torque sensor 108 . The motor speed sensor 107 and the motor torque sensor 108 measure the speed and torque of the MGU 38 , respectively. As the electric hybrid vehicle 10 includes more than one MGU, the drive diagnostic module 102 may receive the motor speed and torque of more than one MGU. For example, the drive diagnostic module 102 may also receive the motor speed and torque of the second MGU 40 .
The drive diagnostic module 102 generates various signals 110 based on the engine speed, the motor speed, and the motor torque. The HCP 104 receives the signals 110 from the drive diagnostic module 102 . The HCP 104 determines a requested motor torque 112 for an MGU based on the received signals 110 . While the HCP 104 is shown as determining the requested motor torque 112 for the MGU 38 , the HCP 104 may determine a requested motor torque for each of the MGUs 38 and 40 .
The MCP 106 receives the requested motor torque 112 from the HCP 104 and controls the torque of the first MGU 38 based on the requested motor torque 112 . For example, the MCP 106 may cause power to be supplied to the MGU 38 in an amount that allows the MGU 38 to produce the requested motor torque 112 . In other words, the MCP 106 controls the torque of the MGU 38 based on the requested motor torque 112 . As such, it is desirable to ensure that the torque commanded by the MCP 106 accurately corresponds to the requested motor torque 112 .
The control module 100 may include multiple layers of security/diagnostics to ensure accuracy and consistency between the HCP 104 and the MCP 106 . For example, one layer of diagnostics may relate to diagnostics of basic components and subsystems such as voltage and current sensors, temperature sensors, and resolver performance diagnostics. Another layer of diagnostics may relate to an independent calculation of achieved motor torque. This independent calculation of the achieved motor torque may be implemented using separate memory locations for software, calibration variables, and static variables. Values used in the calculation may be verified (e.g., using checksum verification) between different execution loops.
Yet another layer of diagnostics may be implemented to prevent software execution and/or processor faults of the MCP 106 . For example only, the control module 100 may include a processor such as a Programming Logic Device (PLD) processor 120 . While the PLD processor 120 is shown as being located external to the MCP 106 , the PLD processor 120 may be located in any suitable location.
The PLD processor 120 may send a seed value to the MCP 106 . The MCP 106 determines a return key value based on the seed value and transmits the return key to the PLD processor 120 . The PLD processor 120 determines the functionality of the MCP 106 based on the return key (e.g. by comparing the return key to an expected key). When the return key does not match the expected key, the PLD processor 120 may implement remedial actions. For example, the PLD processor 120 may reset the MCP 106 and put the first MGU 38 into a secure shutdown mode.
When a fault is detected, the PLD processor 120 and/or the MCP 106 may initiate a secure shutdown mode for the MGU 38 . A procedure for putting the MGU 38 into the secure shutdown mode may follow one or more shutdown paths. A shutdown path may include a particular sequence of measurements and calculations involving the MGU 38 . While the principles of the present application will be discussed as they relate to the MGU 38 , the principles of the present application are also applicable to the second MGU 40 and/or any other MGU.
The control module 100 may perform one or more shutdown path tests to determine whether the secure shutdown mode is functioning properly. For example, the control module 100 may initiate the shutdown path tests at vehicle startup (e.g., at ignition). The shutdown path tests may ensure that the MCP 106 and/or the PLD processor 120 can properly shut down the first MGU 38 when one or more components (e.g., sensors) malfunction and/or when the control module 100 requests a vehicle shutdown. In various implementations, the control module 100 includes a fault diagnostic module 122 that performs the shutdown path tests.
Shutdown path tests according to the present disclosure may include, but are not limited to, a Three Phase Short test and a Three Phase Open test. At vehicle startup, the capability of the MCP 106 to conduct one or more of these shutdown tests is verified. Inability to verify the shutdown tests may indicate defects in, for example, the first MGU 38 , power stage, and/or the MCP 106 .
The fault diagnostic module 122 may initiate remedial action if it is unable to verify the proper performance of the shutdown tests. For example only, the fault diagnostic module 122 may set a fault code, illuminate an accessory light within the hybrid vehicle, and/or disable operation of the MGU 38 . The fault diagnostic module 122 may disable operation of one of the MGU 38 via the power control device 41 , by disabling the MGU 38 directly, and/or in any other suitable manner.
Referring now to FIG. 3 , a method 200 of verifying the Three Phase Short test begins in step 202 . The method 200 determines a rotor position of a rotor within the first MGU 38 in step 204 . For example only, the rotor position may be determined using a resolver or a rotary encoder. In step 206 , the method 200 determines a nearest phase angle to the rotor position.
The first MGU 38 may be operated in a predetermined number of phases, such as three phases (e.g., phases A, B, and C). Each of the phases includes a positive portion (+) and a negative portion (−). For example, for the three phases, the phase angles may be A+, A−, B+, B−, C+, and C−. The nearest phase angle determined in step 206 may be determined based on one of these phase angles. The method 200 commands a d-axis current (i.e., an aligning current) based on the determined phase angle in step 208 . In other words, in step 208 the method 200 commands a current sufficient to align the rotor with the nearest phase angle.
The method 200 determines whether the rotor is properly aligned with the nearest phase angle in step 210 . If true, the method 200 continues to step 211 . If false, the method 200 returns to step 208 and continues to control the current until the rotor is properly aligned with one of the phase angles.
The method 200 may determine whether the rotor is properly aligned with the nearest phase angle, for example, based on a comparison of currents through each of the phases with a respective threshold. For example only, a first threshold corresponding to the phase with which the rotor is aligned may be set based on the aligning current. A second threshold corresponding to the other two phases (i.e., the phases with which the rotor is not aligned) may be set based on half of the first threshold. In other words, the second threshold may be set based on half of the aligning current. In various implementations, the first and second thresholds may be set based on a predetermined amount or percentage less than the aligning current and half of the aligning current, respectively. The method 200 may determine that the rotor is properly aligned when the phase currents are greater than their respective thresholds.
In step 211 , the method 200 measures of the phase currents for each of the phases. The method 200 may also record the phase currents. These phase currents will be referred to as the base phase currents. The method 200 initializes a counter with a value set for the Three Phase Short test in step 212 . For example only, the counter value may be set based on a period of time calibrated based on characteristics of the MGU 38 . The counter value is used to determine the number of iterations of the test. The method 200 determines a PWM duty cycle for the test in step 214 . For example, the PWM duty cycle may be determined to create a short circuit condition of all three phases.
In step 215 , the method 200 controls the duty cycle to create the shorted condition in all of the phases. For example only, the method 200 may control the power control device 41 according to the PWM duty cycle. The method 200 sums the respective phase currents in step 216 . The method 200 decrements the counter value in step 218 . In step 220 , the method 200 determines whether the counter value is zero. If true, the method 200 continues to step 221 . If false, the method 200 repeats steps 215 through 220 and repeats summing the respective phase currents.
In step 221 , the method 200 calculates respective normalized phase currents for each of the phases. For example only, the method 200 may calculate the normalized phase currents using the equation:
NC N = SC N BC N ,
where NC N is the normalized current of the Nth phase, SC N is the summed phase current of the Nth phase as determined after the final iteration of step 216 , and BC N is the base current of the Nth phase as determined in step 211 multiplied by the initial counter value. The method 200 determines whether the respective normalized currents are within a calibrated range in step 222 . If true, the method 200 indicates that the test passed in step 224 . If false, the method indicates that the test failed in step 226 . In other implementations, the method 200 may determine that the test has failed when one or more of the respective normalized currents is greater than or less than a respective calibrated value.
The method 200 may also enable or disable operation of the MGU 38 after steps 224 or 226 are performed, respectively. The method 200 then ends. Alternatively, the method 200 may return to step 202 if the test has failed. For example, the method 200 may allow a predetermined period of time after the test has failed in order to pass the test.
Referring now to FIG. 4 , a method 300 of verifying the Three Phase Open test begins in step 302 . The method 300 determines a rotor position of a rotor within the MGU 38 in step 304 . For example only, the method 300 may determine the rotor position using a resolver or a rotary encoder. In step 306 , the method 300 determines a nearest phase angle to the rotor position.
The MGU 38 may be operated in a predetermined number of phases, such as three phases (e.g., phases A, B, and C). Each of the phases includes a positive portion (+) and an negative portion (−). For example, for the three phases, the phase angles may be A+, A−, B+, B−, C+, and C−. The nearest phase angle determined in step 306 may be determined based on one of these phase angles. In step 308 , the method 300 commands a d-axis current (i.e., an aligning current) based on the nearest phase angle. In other words, in step 308 the method 300 commands a current sufficient to align the rotor of the MGU 38 the nearest phase angle.
The method 300 determines whether the rotor is properly aligned with the nearest phase angle in step 310 . If true, the method 300 continues to step 311 . If false, the method 300 returns to step 308 and continues to control the current until the rotor is properly aligned with one of the phase angles.
The method 300 may determine whether the rotor is properly aligned based on, for example, a comparison of currents through each of the phases with a respective threshold. For example only, a first threshold corresponding to the phase with which the rotor is aligned may be set based on the aligning current. A second threshold corresponding to the other two phases (i.e., the phases with which the rotor is not aligned) may be set based on half of the first threshold. In other words, the second threshold may be set based on half of the aligning current. In various implementations, the first and second thresholds may be set based on a predetermined amount or percentage less than the aligning current and half of the aligning current, respectively. The method 300 may determine that the rotor is properly aligned when the phase currents are greater than their respective thresholds.
In step 311 , the method 300 measures of the phase currents of each of the phases. The method 300 may also record the phase currents. These phase currents will be referred to as the base phase currents. The method 300 initializes a counter with a value for the Three Phase Open test in step 312 . For example only, the counter value may be based on a period of time calibrated based on characteristics of the MGU 38 . The counter value is used to determine the number of iterations of the test.
In step 315 , the method 300 controls the duty cycle to create an open circuited condition in all of the phases. For example only, the method 300 may control the power control device 41 according to the PWM duty cycle. The method 300 sums the respective phase currents in step 316 . The method 300 decrements the counter value in step 318 . In step 320 , the method 300 determines whether the counter value is zero. If true, the method 300 continues to step 321 . If false, the method 300 repeats steps 315 through 320 and repeats summing the respective phase currents.
In step 321 , the method 300 calculates respective normalized phase currents for each of the phases. For example only, the method 300 may calculate the normalized phase currents using the equation:
NC N = SC N BC N ,
where NC N is the normalized current of the Nth phase, SC N is the summed phase current of the Nth phase as determined after the final iteration of step 316 , and BC N is the base current of the Nth phase as determined in step 311 multiplied by the initial counter value. The method 300 determines whether the respective normalized currents are each less than a threshold in step 322 . If true, the method 300 indicates that the test passed in step 324 . If false, the method indicates that the test failed in step 326 .
The method 300 may also enable or disable operation of the MGU 38 after steps 324 or 326 are performed, respectively. The method 300 then ends. Alternatively, the method 300 may return to step 302 if the test has failed. For example, the method 300 may allow a predetermined period of time after the test has failed in order to pass the test.
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification, and the following claims.
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A diagnostic system for a hybrid vehicle comprises a motor control module and a fault diagnostic module. The motor control module controls torque output of an electric motor having a predetermined number of phases. The fault diagnostic module determines a position of a rotor of the electric motor, aligns the rotor with a phase angle of one of the phases, selectively diagnoses a fault based on a current of at least one of the phases, and selectively disables the electric motor based on the diagnosis.
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FIELD OF INVENTION
The present invention relates generally to a hybrid electric vehicle (HEV), and specifically to a strategy to control engaging and disengaging a clutch used to connect an engine to the powertrain of an HEV.
BACKGROUND OF INVENTION
The need to reduce fossil fuel consumption and emissions in automobiles and other vehicles predominately powered by internal combustion engines (ICEs) is well known. Vehicles powered by electric motors attempt to address these needs. Another alternative solution is to combine a smaller ICE with electric motors into one vehicle. Such vehicles combine the advantages of an ICE vehicle and an electric vehicle and are typically called hybrid electric vehicles (HEVs). See generally, U.S. Pat. No. 5,343,970 to Severinsky.
The HEV is described in a variety of configurations. Many HEV patents disclose systems where an operator is required to select between electric and internal combustion operation. In other configurations, the electric motor drives one set of wheels and the ICE drives a different set.
Other, more useful, configurations have developed. For example, a series hybrid electric vehicle (SHEV) configuration is a vehicle with an engine (most typically an ICE) connected to an electric motor called a generator. The generator, in turn, provides electricity to a battery and another motor, called a traction motor. In the SHEV, the traction motor is the sole source of wheel torque. There is no mechanical connection between the engine and the drive wheels. A parallel hybrid electrical vehicle (PHEV) configuration has an engine (most typically an ICE) and an electric motor that work together in varying degrees to provide the necessary wheel torque to drive the vehicle. Additionally, in the PHEV configuration, the motor can be used as a generator to charge the battery from the power produced by the ICE.
A parallel/series hybrid electric vehicle (PSHEV) has characteristics of both PHEV and SHEV configurations and is sometimes referred to as a parallel/series “split” configuration. In one of several types of PSHEV configurations, the ICE is mechanically coupled to two electric motors in a planetary gear-set transaxle. A first electric motor, the generator, is connected to a sun gear. The ICE is connected to a carrier. A second electric motor, a traction motor, is connected to a ring (output) gear via additional gearing in a transaxle. Engine torque can power the generator to charge the battery. The generator can also contribute to the necessary wheel (output shaft) torque if the system has a one-way clutch. The traction motor is used to contribute wheel torque and to recover braking energy to charge the battery. In this configuration, the generator can selectively provide a reaction torque that may be used to control engine speed. In fact, the engine, generator motor and traction motor can provide a continuous variable transmission (CVT) effect. Further, the HEV presents an opportunity to better control engine idle speed over conventional vehicles by using the generator to control engine speed.
The desirability of combining an ICE with electric motors is clear. There is great potential for reducing vehicle fuel consumption and emissions with no appreciable loss of vehicle performance or driveability. The HEV allows the use of smaller engines, regenerative braking, electric boost, and even operating the vehicle with the engine shutdown. Nevertheless, new ways must be developed to optimize the HEV's potential benefits.
One such area of HEV development is controlling the engagement and disengagement of the engine from the HEV powertrain. Frequently, this is done using a two-way clutch in parallel HEV's. A two-way clutch allows the engine to drive the motor, and allows the engine and motor to drive the vehicle. Clutch control strategies for HEVs are known in the art. See generally, U.S. Pat. No. 5,979,257 to Lawrie and U.S. Pat. No. 5,943,918 to Reed, Jr. et al. Nevertheless, none are designed to control engaging and disengaging a two-way clutch to connect the engine from a parallel HEV.
SUMMARY OF INVENTION
Accordingly, an object of the present invention is to provide a strategy to control engaging and disengaging a clutch used to connect an engine to the powertrain of an hybrid electric vehicle (HEV).
Briefly, the invention provides a system for clutch control in an HEV. The system, which controls a clutch for connecting an engine to the powertrain of the HEV includes a controller programmed to determine a filtered speed error of the engine and a starter/motor and to determine an engine run command. Monitoring devices operatively connected to the engine and the starter/motor are connected to output data representing the engine and starter/motor speeds to the controller. The controller is programmed to generate a clutch position command, dependent on the data, to a servo-actuator connected to the clutch.
The invention, further, provides methods for controlling such a clutch including the steps of determining an engine run command, determining a filtered speed error of the engine and a starter/alternator (or starter/motor) and generating a clutch position command. The step of determining an engine run command may include the steps of determining whether the clutch is engaged, determining whether the engine is at least spinning at a predetermined idle speed, and commanding a fuel request to the engine when the clutch is engaged and the engine is spinning at least at the predetermined idle speed. The step of determining a filtered speed error may include the steps of determining a speed error, determining a scaled speed error; and inputting the scaled speed error to a digital lowpass filter.
Other features and advantages of the present invention will become more apparent to persons having ordinary skill in the art to which the present invention pertains from the following description taken in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing advantages and features, as well as other advantages and features will become apparent with reference to the description and figures below, in which like numerals represent like elements and in which:
FIG. 1 illustrates a general parallel hybrid electric powertrain configuration.
FIG. 2 illustrates a clutch control operation logic of the present invention.
FIG. 3 illustrates a 20 second simulation of the present invention.
FIG. 4 illustrates an expanded view of the 3 to 5 second period of the FIG. 3 simulation.
FIG. 5 illustrates an expanded view of the 16 to 18 second period of the FIG. 3 simulation.
FIGS. 6A-C illustrates a control strategy using the present invention.
DETAILED DESCRIPTION
The present invention relates to hybrid electric vehicles (HEVs) and, more particularly, a strategy to control engaging and disengaging a clutch used to connect an engine to the powertrain of an HEV. The preferred embodiment of the present invention uses a controller for engaging and disengaging a dry two-way clutch used for connecting an engine to a powertrain in a parallel hybrid electric vehicle (PHEV).
FIG. 1 illustrates a possible PHEV powertrain to demonstrate the present invention and is generally indicated at 18 . This powertrain 18 has an engine 20 (such as a conventional 2.0 L spark-ignited, internal combustion engine (ICE)) and a combination starter/motor 24 to supply motive torque for the vehicle. The starter/motor 24 is configured and sized to not only provide motive torque, but also to spin the engine 20 for starting purposes. For the present invention a 60 horse power (HP) starter/motor 24 can be used. The vehicle powertrain also has a disconnect clutch (“clutch”) 22 positioned between the engine 20 and starter/motor 24 . The clutch 22 can be a two-way dry disconnect clutch known in the art. The clutch 22 can be connected to the engine 20 on an engine flywheel and can connect to the starter/motor 24 on its rotor shaft 50 . A servo-actuator 26 housed together with the clutch 22 can activate the clutch 22 to a closed and open position. The servo-actuator 26 can electronically control the engagement and disengagement of the clutch 22 by applying or releasing pressure on the friction components. These mechanisms are well known in the art.
The clutch 22 in a closed position allows the engine 20 to connect to the powertrain 18 . This closed position can serve three HEV powertrain functions. First, it allows the engine 20 to spin the starter/motor 24 to generate power to charge and discharge a high-powered energy storage device such as a battery 28 (the battery 28 is electrically connected to the starter/motor 24 ). Second, it allows the starter/motor 24 to spin the engine 20 during engine 20 start-up. And third, it allows both the engine 20 and starter/motor 24 to drive the vehicle powertrain 18 simultaneously. In an open position, the engine 20 is disconnected from the vehicle powertrain 18 . The clutch 22 would be open if the engine 20 is not running.
As illustrated in FIG. 1 , the powertrain also has: a forward clutch 30 connected to the starter/motor 24 ; an electronically controlled converterless transmission (ECLT) 32 connected to the forward clutch 30 ; a differential and half-shafts combination (“differential”) 34 connected to the ECLT 32 ; and at least one drive wheel 36 connected to the differential 34 . Any of the vehicle wheels can be connected to a mechanical braking system 42 activated by operator using a brake activation means such as a brake pedal 44 well known in the art. Also, this powertrain is for illustrative purposes only. Several other powertrain configurations are possible using the present invention.
Each component of the illustrated powertrain 18 can have a sensor and an associated controller. A vehicle system controller (VSC) 38 can receive sensor input and control the components accordingly in this HEV configuration by connecting to each component's controller. Alternatively, controllers can be physically combined in any combination or can stand as separate units. The VSC 38 illustrated in FIG. 1 can communicate with the servo-actuator 26 and other components through a communication network such as a controller area network (CAN) 40 . Sensor inputs can be included for the starter/motor 24 speed, engine 20 speed, clutch 22 position, and the position of driver operated braking means and accelerator means. The sensor for the accelerator means can be an accelerator position sensor 46 .
The present invention is a strategy to control the servo-actuator 26 to open and close the clutch 22 . This clutch controller as illustrated is within VSC 38 . In this illustration, the controller can generate a position command (Clutch_Position_Cmd) to the servo-actuator 26 as an eight-bit integer that represents a scaled, fixed-point representation of the interval 0.0 to 1.0, divided into 256 equal steps of value {fraction (1/256)}. The servo-actuator 26 can interpret the Clutch_Position_Cmd according to Table 1 below.
TABLE 1
Condition
Clutch State
Clutch_Pos_Cmd > 0.85
Disengaged
0.15 < Clutch_Pos_Cmd < 0.85
Slipping
Clutch_Pos_Cmd < 0.15
Engaged
For example, the VSC 38 can command only the starter/motor 24 , to provide motive force to the powertrain 18 . This command can include turning off the engine 20 and disconnecting the clutch 22 . The clutch 22 can be completely disengaged by generating a Clutch_Position_Cmd>0.85. Any position value between 0.5 and 1.0 will result in activating the servo-actuator 26 to completely disengage the clutch 22 . Similarly, if the VSC 38 commands the engine 20 to connect to the powertrain 18 , the controller of the present invention can generate a Clutch_Position_Cmd<0.15. Any position value between 0 and 0.15 will result in activating the servo-actuator 26 to completely engage the clutch 22 .
During clutch 22 transition from an engaged to disengaged state (and from disengaged to engaged) there is a period of decreasing (and increasing) clutch 22 engagement. This clutch 22 “slipping” state is a nonlinear relationship between the value of Clutch_Position_Cmd and the degree of clutch 22 engagement. For example, more slip is commanded as the eight-bit position value approaches 0.85 (i.e., less torque transmitted through the clutch 22 ). Similarly, less slip can be commanded as the position approaches 0.15 (i.e., more torque is transmitted through the clutch 22 ) and the closer the clutch is to being fully engaged.
The clutch 22 controller of the present invention controls clutch 22 slip during engagement and disengagement to provide a smooth transition, transparent to the driver in terms of noise, vibration and harshness (NVH) and performance feel. This smooth transition is important since an hybrid electric vehicle (HEV) can frequently transition between the various HEV operating modes such as: engine 20 only, starter/motor 24 only, engine 20 with starter/motor 24 boost, charging, and regenerative braking.
The present invention is a disconnect clutch control (Disconnect_Clutch_Control) and can have a top level structure of three main strategies: (1) Determ_Engine_Run_Cmd, (2) Determ_Filtered_Speed_Error, and (3) Generate_Clutch_Position_Cmd.
(1) Determ_Engine_Run_Cmd
One of the two outputs of the Disconnect_Clutch_Control can be an engine run command (Engine_Run_Cmd), where engine fueling is commanded to start (=1) or stop (=0). The other output is a Clutch_Position_Cmd. The Engine_Run_Cmd is a modified version of a VSC 38 signal Fuel_Engine_Request and can be set high whenever the engine 20 needs to be turned on to provide motive power or charge the battery 28 . Traditionally, once the VSC 38 determines the engine 20 needs to be started, it sets Fuel_Engine_Request high (=1) to commence engine 20 fueling. Nevertheless, if the clutch 22 is not yet engaged and the engine 20 is not rotating at sufficient speed, fueling must be prohibited. Therefore, the Determ_Engine_Run_Cmd delays the engine 20 fueling until the starter/motor 24 in combination with clutch 22 engagement has brought the engine 20 up to or beyond its “idle speed,” which in this embodiment can be 750 rpm. Only then is Fuel_Engine_Cmdset high and engine 20 fueling begins (See steps 82 , 86 , 90 and 92 ).
A sample code representation of the above description and the contents of FIG. 3 , Determ_Engine_Run_Cmd, is: IF (Clutch_Pos_Actual<0.85) AND (Eng_Spd_GT_ 750 =1) AND (Fuel_Engine_Request=1), THEN (Engine_Run_Cmd=1) ELSE (Engine_Run_Cmd=0) END.
Here:
Clutch_Pos_Actual<0.85: Clutch is slipping.
Eng_Spd_GT_ 750 =1: Engine speed is greater than 750 rpm.
Fuel_Engine_Request=1: The VSC has decided that the ICE needs to be running.
Engine_Run_Cmd=1: Begin fueling the ICE.
Engine_Run_Cmd=0: Do not fuel the ICE.
(2) Determ_Filtered_Speed_Error
This procedure determines the Speed_Error (rpm) between the starter/motor 24 speed and the engine 20 speed as a measure of clutch 22 slip (step 72 below). A very small gain multiplies the speed error to scale it to a range of approximately ±1 for use in the remainder of the strategy. This Scaled_Speed_Error (see step 70 below) can be the input to a Digital_Lowpass_Filter. This filter, which is a standard digital filter known in the art, can be determined by the following difference equation (see step 72 ):
Filtered_Speed_Error (k)=TIME_CONSTANT* Scaled_Speed_Error(k)+(1−TIME_CONSTANT)*Filtered_Speed_Error (k−1)
The value “k” refers to the current determination time step and “k−1” the determination from the previous time step. TIME_CONSTANT is a number between 0.0 and 1.0. The closer it is to 0.0, the more heavily filtered, or smoothed, the output Filtered_Speed_Error (k) will be; conversely, the closer it is to 1.0, the less filtered it will be. Also, the heavier the filtering, the slower the clutch 22 will be allowed to be engaged; consequently, the choice of TIME_CONSTANT is the key to proper tuning of the strategy. In one embodiment the constant can be TIME_CONSTANT=0.03. Here, very heavy filtering is performed to feather the clutch 22 engagement, ensuring a seamless, imperceptible transition from one HEV driving mode to the next.
(3) Generate_Clutch_Positon_Cmd
The primary output of Disconnect_Clutch_Control of the present invention is the Clutch_Pos_Cmd, (see steps 78 , 92 , and 99 below). This command can be sent over the CAN 40 to the clutch servo-actuator 26 to position the clutch 22 plates according to the command. The servo-actuator 26 has a sensor to determine the actual clutch 22 position, Clutch_Position_Actual, and sends it back to the VSC 38 to the Disconnect_Clutch_Control strategy where it is used to determine Determ_Engine_Run_Cmd as previously described. The Generate_Clutch_Position_Cmd contains Switching_Logic_Subsystem to determine Eng_Spd_GT_ 750 (Engine Speed>750 rpm) and sends it to Determ_Engine_Run_Cmd, and Engine_Off_and_Brk. Braking_Logic, determined in another VSC 38 procedure (see step 62 below), is high (=1) when the braking device such as a brake pedal 44 is applied or if the accelerator pedal position sensor 46 detects the accelerator is NOT applied, for instance, during braking or coasting. Braking_Logic is low (=0) when the accelerator pedal is applied. Switching_Logic_Subsystem logically ANDs Braking_Logic with Eng_Spd_GT_ 750 to produce Engine_Off_and_Brk. For example, with the mechanical brake applied (or, neither brake and accelerator pedal are not applied) and the engine 20 speed is greater than 750 rpm, this signal is high (=1), setting Clutch_Position_Cmd=1.0 to engage the clutch 22 fully. If the accelerator is applied, e.g., the operator's foot is on the accelerator pedal, Engine_Off_and_Brk=0 and the switch will pass through the lower signal whose determination is described next.
There can be several ways to determine engagement and disengagement of the clutch 22 . Simply, if Crank_Engine_Cmd=1 or if Fuel_Engine_Request=1 (in other words, if the VSC 38 has decided to crank the engine 20 or, it is already cranked and is ready to be fueled) then Filtered_Speed_Error is passed through the switch and subtracted from 1 (the output of Crank_Engine_Cmd OR Fuel_Engine_Request). This operation is why it is necessary to scale Speed_Error to Scaled_Speed_Error in Determ_Filtered_Speed_Error. The scaling factor is chosen so that when the clutch 22 is asked to engage, Filtered_Speed_Error is at some value near 0.5.
FIG. 2 can illustrate one embodiment the present invention Generate_Clutch_Positon_Cmd logic. FIG. 2 shows several variables as a function of time (5 seconds) including: Crank —Engine _Cmd 100 , Clutch_Step_Input 102 , Filtered_Speed_Error 104 , Scaled_Speed_Error 106 , Clutch_Position_Cmd 108 , and Clutch_Pos_Actual 110 . In the example of FIG. 2 , the Filtered_Speed_Error 102 value is roughly 0.4 when Crank_Engine_Cmd goes high. Clutch_Step_Input 102 =1−Filtered_Speed_Error 104 is then around 0.6 resulting in Clutch_Positon_Cmd 108 =approximately 40 after passing through the linear interpolation table Clutch_Pos_Map (Table 2, and step 99 below).
TABLE 2
Clutch_Pos_Map
Clutch_Step_Input
Clutch State
−1.0
Disengaged
−0.5
Disengaged
0
Disengaged
0.5
Slipping
1.0
Engaged
This Clutch_Position_Cmd is sent to the clutch's servo-actuator 26 that compresses the clutch 22 plates to achieve this commanded position. The bottom trace of FIG. 2 shows the Clutch_Pos_Actual from the sensor output of the clutch position sensor. The mechanical dynamics of the clutch mechanism produce the filtering effect between the control signal, Clutch_Position_Cmd, and the physically measured Clutch_Pos_Actual.
The effect of Digital_Lowpass Filter described above is evident in FIG. 2 , Filtered_Speed_Error 104 and Scaled_Speed_Error 106 . If the value of TIME_CONSTANT described above was not sufficiently small to provide enough smoothing, Filtered_Speed_Error 104 would tend to be more like Scaled_Speed_Error 106 (which was filtered to obtain Filtered_Speed_Error 104 ) resulting in very oscillatory engagement and disengagement processes and, therefore, unsatisfactory performance.
FIG. 3 shows a 20 second simulation of one embodiment of the present invention including: Clutch_Pos_Actual 120 , Eng/Motor Speed rpm 122 , Eng_Cranking 124 , Engine_Run_Cmd 126 , and Eng_Off & Braking 128 . FIG. 3 shows that the clutch 22 begins to engage when the engine 20 begins cranking. FIG. 3 also shows a 3 to 5 second clutch 22 engagement period. The clutch 22 goes through a short period of slipping until the engine 20 speed equals the starter/motor 24 speed. The clutch 22 is then fully engaged while the vehicle operator speeds away until just after 12 seconds. Just after 12 seconds, the vehicle operator releases the accelerator pedal and either begins braking or is coasting with neither brake nor accelerator depressed. The clutch 22 stays engaged through this coast down period and disengages just before the 18 second mark when the engine 20 speed has dropped below 750 rpm. FIG. 4 expands the engagement phase of FIG. 3 (3 to 5 seconds) and FIG. 5 expands the disengagement phase of FIG. 3 (16 to 18 seconds).
The possible control strategy for the controller of the present invention is illustrated in FIGS. 6A-6C . It can be housed within the VSC 38 . Many other control strategies using the present invention are possible. This strategy can start and end with each drive cycle (i.e., between “key-on” and “key-off”). In FIGS. 6A-6C , the illustrated embodiment starts at Step 60 and determines whether the vehicle controller outputs have been initialized (Outputs_Initialized). Here, the outputs need to be initialized, given a known value, the first time through the algorithm after startup to ensure that the outputs are not set to an unwanted state by the power-up sequence of the controller. If yes, the strategy proceeds to step 62 . If no, the strategy proceeds to step 64 and commands “Initialize_Outputs” including: Clutch_Position_Cmd=Disengaged and Fuel_Engine_Cmd=False. The strategy proceeds next to step 66 and commands Outputs_Initialized=True and proceeds to step 62 . Once initialized in the first pass through the algorithm, subsequent output values are determined by the algorithm. As described above, the Clutch_Position_Cmd, for this step could be an eight-bit integer>0.85.
At step 62 the strategy is commanded to read various vehicle inputs such as other VSC 38 commands and inputs various vehicle sensor outputs. In the illustration presented in FIGS. 6A-C , the following examples are included: Crank_Engine_Cmd, Engine_Speed, Motor_Speed, Braking_Logic, Clutch_Position_Actual, Fuel_Engine Request. These examples represent various inputs that would be necessary to smoothly transition a clutch 22 between engaged and disengaged states. Crank_Engine_Cmd alerts the strategy whether the engine 20 has been commanded by the VSC 38 to start. Engine_Speed can originate from an engine 20 speed sensor well known in the art. Similarly, Motor_Speed can originate from a starter/motor 24 speed sensor known in the art. The difference in Engine_Speed and Motor_Speed can be used to determine actual clutch 22 slippage (see below). If a mechanical braking means such as a brake pedal 44 is depressed and a vehicle accelerator means such as an accelerator pedal is NOT depressed, then Braking_Logic=True. Otherwise, Braking_Logic=False. Accelerator pedal position is detected by the accelerator position sensor 46 . The Clutch_Position_Actual is the actual position of the clutch 22 in terms of engagement and disengagement sensed by a clutch 22 position sensor. The Fuel_Engine_Request is a VSC 38 command the controller of the present invention can use to indicate whether the engine 20 is running.
Once the inputs are read in step 62 , the strategy next proceeds to step 68 and determines Speed_Error. Speed_Error is the difference between the starter/motor 24 speed and engine 20 speed.
Next, the strategy proceeds to step 70 to determine Scaled_Speed_Error. The Scaled_Speed_Error multiples the Speed_Error determined in step 68 by Speed_Gain as described above.
Next the strategy proceeds to step 72 to determined Filtered_Speed_Error. The Filtered_Speed_Error as described above is:
(Time Constant) Scaled_Speed_Error)(k)+(1 Time Constant)*Filtered_Speed_Error) (k 1)
Next, the strategy proceeds to step 74 and determines whether the VSC 38 has requested fuel to the engine 20 . If yes, the strategy proceeds to step 80 . If no, the strategy proceeds to step 76 and determines whether the VSC 38 has commanded the Crank_Engine_Cmd. If yes, the strategy proceeds to step 80 . If no, the strategy proceeds to step 78 and commands the clutch to disengage (i.e., Clutch_Position_Cmd=Disengaged), then proceeds to step 80 .
At step 80 , the strategy determines whether the Clutch_Position_Cmd is commanding the clutch 22 to slip. If no, the Fuel_Engine_Cmd is commanded false at step 82 and the strategy returns to the beginning. If yes, the strategy proceeds to step 84 and determines if the engine speed is greater than a predetermined start speed (as suggested above, a start speed could be under 750 RPM). If no at step 84 , the strategy commands the Fuel_Engine_Cmd=False and proceeds to step 94 .
If yes at step 84 , the strategy determines if the Braking_Logic=true (as described above) at step 88 . If no, the strategy proceeds to step 90 and commands Fuel_Engine_Cmd=True, then proceeds to step 94 .
If yes at step 88 , the strategy commands the clutch 22 to engage (Clutch_Positon_Cmd=Engaged) and the stop fuel to the engine 20 (Fuel_Engine_Cmd=False). The strategy next returns to the beginning.
At step 94 , the strategy determines Clutch_Step_Input as a value (Temp) of 1 the Filtered_Speed_Error (from step 72 ) and proceeds to step 95 . At step 95 , the strategy determines whether “Temp” from step 94 is less than 1. If yes, the strategy proceeds to step 96 and sets the Filtered_Speed_Error to 1 in step 96 and proceeds to step 99 .
If no at step 95 , the strategy proceeds to step 97 and determines whether “Temp” is >−1. If no, the strategy proceeds to step 99 . If yes, the strategy proceeds to step 98 and sets the Filtered_Speed_Error to 1, then proceeds to step 99 .
At step 99 , the procedure performs a linear interpolation to smoothly transition the engagement of the clutch 22 .
To summarize, step 96 and step 98 are used to limit Temp to +1 or 1 if the calculation in 94 results in a value of Temp greater than +1 or less than 1. When Temp is between 1 and 1, the algorithm will proceed from step 94 to step 95 to step 97 and to step 99 . Command values can have only positive values between 0 and 1, whereas Clutch_Step_Input takes on values between 1 and 1.
The above-described embodiments of the invention are provided purely for purposes of example. Many other variations, modifications, and applications of the invention may be made.
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This invention is a control system for a clutch for connecting an engine to the powertrain of an HEV. The system includes a controller programmed to determine a filtered speed error of the engine and a starter/motor and to determine an engine run command. Monitoring devices operatively connected to the engine and the starter/motor are connected to output data representing the engine and starter/motor speeds to the controller. The controller is programmed to generate a clutch position command, dependent on the data, to a servo-actuator connected to the clutch. The invention, further, provides methods for controlling such a clutch including the steps of determining an engine run command, determining a filtered speed error of the engine and a starter/motor and generating a clutch position command.
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FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a hydraulically actuatable directional control valve, particularly a directional proportional control valve, which is to be controlled by electromagnetically actuated pilot valves of small nominal sizes.
In connection with these valves, it is known to fasten the pilot valves of small nominal size having a housing of their own to the lateral end surfaces of the housing of the directional control valve and to establish the hydraulic connection and of these pilot valves with the tank and pressure connection with the directional control valve via bored channels in the housing of the directional control valve. Since the connection pattern of the known pilot valves of small nominal size has results in connecting channels of small diameter at a slight distance from each other, the introduction of these connecting channels in the form of bore holes requires a considerable manufacturing expense. Instead of pilot valves which are fastened to the side of the housing of the directional control valve, it is also known to develop the pilot valves as insertion cartridges and screw them into the housing of the directional control valve parallel to the actuation axis of the servo-piston of the directional control valve and to connect the pilot valves hydraulically to the directional control valve by separate bore holes in the housing of the directional control valve. Such a development and arrangement of the pilot valves in the housing of the directional control valve requires expensive production of the connecting bore holes, particularly as they must close in pressure-tight fashion, without leakage towards the outside.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to create a development and arrangement of the pilot valves on the directional control valve which assures an inexpensive manufacture of the directional control valve with pilot valves, particularly in the case of mass production.
According to the invention, due to the fact that the hydraulic connecting of the pilot valves developed as insertion cartridges to the directional control valve is effected via channels cast in the housing of the directional control valve and the connections of the insertion cartridges of each pilot valve are adapted to the geometry of the cast channels, inexpensive mass production of these valves can, in particular, be obtained in a simple manner.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other objects and advantages in view, the present invention will become more clearly understood in connection with a detailed description of the sole FIGURE showing in cross-section an embodiment of a hydraulically actuatable directional control valve in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the sole FIGURE of the drawing, 1 is the cast-iron housing of the directional control valve which contains a servo-piston 3 in a passage bore hole 2. The servo-piston is fixed at its end sides 3a, 3b by springs 4, 5 in the initial position shown. The ends of the springs facing away from the servo-piston rest against hollow closure screws 6, 7. The ends of the servo-piston define control spaces 8, 9 which can be acted on by control liquid and are connected via channels 10, 11 to the corresponding outlet spaces 12, 13 of the electromagnetically actuatable pilot valves 14, 15 which are developed as insertion cartridges. The pilot valves are developed as pressure control valves and screwed into corresponding recesses 16, 17 in the cast-iron housing 1.
The control pressure acting in the control spaces 8, 9 displaces the servo-piston 3 against the force of the corresponding springs 4, 5, the consumer connecting channel 20 being connected either to the pump connection P or to the tank connection T, depending on the direction of displacement of the servo-piston. The actuation axes 21, 22 of the pilot valves extend parallel to each other and perpendicular to the actuation axis 23 of the servo-piston 3. As a result, there is a particularly simple channel path for the feeding and discharge of the control liquid to and from the pilot valves.
The connection bore holes 24 which are connected to the source of control pressure agent P1 and the connecting holes 25 of the pilot valves which are connected to the tank connection T match the channels 26, 27 cast in the cast-iron housing which extend parallel to each other, the channel 26 being in communication with the source of control pressure agent P1 and the channel 27 with the tank T. The channel 26 which is connected to the source of control pressure agent P1 is connected via a transversely extending channel-shaped recess 30 with the passage bore 2 for the servo-piston 3. The servo-piston 3 narrows down in the manner of a neck at the entrance place 3c and is therefore of smaller diameter at this place. In this way there is obtained a control edge 3d which cooperates with a corresponding control edge 2d of the passage bore. The control edge 2d results from a widening of the passage bore to a control space 32 which communicates via a connecting channel 31 with the control space 33 of an actuating control piston 34 for a holding piston 35 developed as non-return valve for the consumer (not shown). The actuating control piston has a blind hole 34a with two radially extending bore holes 34b, 34c, in which connection control liquid can be fed from the connecting channel 31 via the bore hole 34b to the control space 33 of the actuating control piston when the control edge 3d of the servo-piston 3 is open and control liquid is to be displaced, via the bore hole 34c of small diameter acting as choke for the setting back of the actuating control piston, from the control space 33 to the space 37 which is connected with the tank connection T.
The servo-piston 3 has control edges 3e, 3f formed by grooves milled in the servo-piston, which control edges, depending on the direction of displacement of the servo-piston, produce the connection of the control space 38 which is connected via the holding piston 35 to the consumer, to the control space 39 which is connected to the source of working pressure agent P, or with the control space 40 which is connected to the tank. Upon actuation of, in each case, an actuation magnet of the corresponding pilot valve, a control pressure corresponding to the electric current fed is set on the pilot valve 14, 15 which pressure is present in the corresponding control space 8, 9 of the servo-piston 3 and pushes the latter against the force of the corresponding opposite spring 4, 5 until the spring force, which increases hereby, corresponds to the control pressure set. Upon actuation of the actuation magnet of the pilot valve 14, the control space 8 of the servo-piston 3 is acted on with the control pressure set on the pilot valve, and the servo-piston is displaced against the force of the opposite spring 5 by an amount corresponding to the value of the control pressure and thus via the control edges 3f of the servo-piston 3 which lie in open position, the control space 38 which is connected to the consumer is connected with the control space 39 connected with the source of working pressure agent so that working pressure agent acts, via the connecting channel 20, on the holding piston 35 which is lifted off from its housing seat 42 by the incoming working agent and from there further, via the consumer connection V, on the consumer (not shown), for instance a lift mechanism. Upon actuation of the actuating magnet of the pilot valve 15, the control pressure in the control space 9 which pressure is set on the pilot valve 15 acts on the servo-piston 3 and displaces it against the force of the opposite spring 4, in which connection the servo-piston 3, via its opened control edges 3e, forms a connection between the control space 38, which is connected via the holding piston 35 to the consumer and the control space 40 which is connected to the tank. At the same time, the surrounding control edge 3d of the servo-piston 3 opens the connection of the source of control pressure agent P1 with the control chamber 33 of the actuating control piston 34 so that the latter, via an intermediate member 43, lifts the holding piston off from its housing seat 42, whereby a connection is formed via the control edge 3e between the consumer (not shown) and the tank.
By the cast channels for the hydraulic connection of the pilot valves to the source of control pressure agent and to the tank as well as to the control spaces of the servo-piston, there results, also for additional apparatus such as the actuatable holding valve, for the consumer a further simplification of the path of the channel in the cast-iron housing of the directional control valve.
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In a hydraulically actuatable directional control valve the servo-piston of which is to be controlled by electromagnetically actuatable pilot valves of small nominal size developed as insertion cartridges integrated in the directional control valve housing, the hydraulic connection between the pilot valves and the directional control valve are effected via channels extending in the directional control valve housing, the channels in the directional control valve housing are produced as cast channels, in particular for mass production, and the connections of the pilot valves are adapted to the size and arrangement of these channels.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application No. 61/094,748, filed on Sep. 5, 2008, in the USPTO, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND
Description of the Related Art
[0002] A conventional protective layer of a PDP comprises double layers that are formed of coating a magnesium oxide powder on a magnesium oxide thin film, wherein the magnesium oxide powder is prepared by vapor deposition. In detail, the magnesium oxide powder for forming the conventional protective layer is prepared by heating magnesium in a chamber and injecting and oxidizing an atmospheric gas, such as oxygen (O 2 ), hydrogen (H 2 ), or argon, into the chamber. The magnesium oxide powder prepared as described above has many defects and relatively many impurities.
[0003] The present embodiments overcome the problems in the related art and provide additional advantages as well.
SUMMARY
[0004] Some embodiments relate to a MgO powder prepared by the method comprising:
[0000] heating Mg in air to a temperature sufficient to generate Mg vapor;
allowing the Mg to react with the air and become naturally oxidized to yield the MgO powder,
wherein the magnesium oxide powder has a first cathode-luminescence spectrum emission peak at a wavelength from about 300 nm to about 370 nm, and a second emission peak at a wavelength from about 600 to about 640 nm,
and wherein the intensity ratio of the first emission peak to the second emission peak is from about 1:0.4 to about 1:0.6.
[0005] In some embodiments, the MgO comprises less than 2 ppm of each of nickel (Ni), iron (Fe), barium (B), silicon (Si), manganese (Mn), chrome (Cr), calcium (Ca), copper (Cu), zirconium (Zr), aluminum (Al), and sodium (Na).
[0006] Some embodiments further comprise a third emission peak at a wavelength from about 700 nm to about 800 nm, wherein the intensity ratio of the first emission peak to the third emission peak is from about 1:0.25 to about 1:0.45.
[0007] Some embodiments relate to a protective layer comprising:
[0000] an MgO having a first cathode-luminescence spectrum emission peak at a wavelength from about 300 nm to about 370 nm, and a second emission peak at a wavelength from about 600 to about 640 nm,
and wherein the intensity ratio of the first emission peak to the second emission peak is from about 1:0.4 to about 1:0.6.
[0008] In some embodiments, the MgO comprises less than 2 ppm of each of nickel (Ni), iron (Fe), barium (B), silicon (Si), manganese (Mn), chrome (Cr), calcium (Ca), copper (Cu), zirconium (Zr), aluminum (Al), and sodium (Na).
[0009] Some embodiments further comprise wherein the magnesium oxide powder has a third emission peak at a wavelength from about 700 nm to about 800 nm and wherein the intensity ratio of the first emission peak to the third emission peak is from about 1:0.25 to about 1:0.45.
[0010] Some embodiments relate to a plasma display panel comprising:
[0000] a front panel through which light is emitted to the outside of the PDP,
a rear panel on which phosphors are disposed,
a plurality of transparent electrodes disposed on a front glass substrate,
bus electrodes disposed on the transparent electrodes in parallel to the transparent electrodes,
a front dielectric layer configured to cover the transparent electrodes and bus electrodes,
a protective layer configured to cover the front dielectric layer, and
a discharge gas,
wherein the protective layer comprises MgO having a first cathode-luminescence spectrum emission peak at a wavelength from about 300 nm to about 370 nm, and a second emission peak at a wavelength from about 600 to about 640 nm,
and wherein the intensity ratio of the first emission peak to the second emission peak is from about 1:0.4 to about 1:0.6.
[0011] In some embodiments, the protective layer include a first protective portion and a second protective portion,
[0000] wherein the first protective portion comprises polycrystalline magnesium oxide,
wherein the second protective portion comprises the MgO.
[0012] In some embodiments, the second protective portion is irregularly formed on the first protective portion.
[0013] In some embodiments, the second protective portion has a maximum intensity from about 0.5 to about 10 times that of the first protective portion.
[0014] In some embodiments, the first protective portion comprises polycrystalline magnesium oxide having a cathode-luminescence spectrum emission peak at a wavelength from about 380 nm to about 400 nm.
[0015] In some embodiments, the MgO comprises less than 2 ppm of each of nickel (Ni), iron (Fe), barium (B), silicon (Si), manganese (Mn), chrome (Cr), calcium (Ca), copper (Cu), zirconium (Zr), aluminum (Al), and sodium (Na).
[0016] Some embodiments further comprise wherein the magnesium oxide powder has a third emission peak at a wavelength from about 700 nm to about 800 nm wherein the intensity ratio of the first emission peak to the third emission peak is from about 1:0.25 to about 1:0.45.
[0017] In some embodiments, the second protective portion covers substantially the entire top surface of the first protective portion.
[0018] In some embodiments, the second protective portion is formed by one selected from the group consisting of patterning and inject printing.
[0019] In some embodiments, the discharge gas comprises Xe.
[0020] In some embodiments, the discharge gas comprises about 10% Xe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other features and advantages of the present embodiments will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
[0022] FIG. 1 is an exploded perspective view of a plasma display panel (PDP) according to an embodiment;
[0023] FIG. 2 is a cross-sectional view taken along line I-I′ of the PDP of FIG. 1 ;
[0024] FIGS. 3A and 3B are graphs illustrating a cathode luminescence spectrum of a material for forming each of protective layers;
[0025] FIGS. 4A and 4B are SEM images of the protective layer according to an embodiment;
[0026] FIGS. 5A and 5B are graphs illustrating a firing voltage and a sustain voltage of each of the protective layers under a discharge gas atmosphere containing 15% by volume of Xenon (Xe);
[0027] FIGS. 6A and 6B are graphs illustrating a firing voltage and a sustain voltage of each of the protective layers under a discharge gas containing 50% by volume of Xenon (Xe); and
[0028] FIGS. 7 and 8 are graphs illustrating photoelectron emission characteristics.
DETAILED DESCRIPTION
[0029] The present embodiments will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments are shown.
[0030] The present embodiments provide a material for forming a protective layer of a PDP which has few defects and few impurities. The present embodiments also provide a method of preparing the material, and a PDP including a protective layer formed of the material.
[0031] According to an embodiment, there is provided a material for forming a protective layer of a PDP, the material comprising a magnesium oxide powder, wherein, when a cathode luminescence spectrum is measured, the magnesium oxide powder has a first emission peak in a wavelength range of from about 300 to about 370 nm, and a second emission peak in a wavelength range of from about 600 to about 640 nm. An intensity ratio of the first emission peak to the second emission peak may be from about 1:0.40 to about 1:0.60.
[0032] Also, the magnesium oxide powder can further comprise a third emission peak in a wavelength range of from about 700 to about 800 nm. An intensity ratio of the first emission peak to the third emission peak may be from about 1:0.25 to about 1:0.45.
[0033] The magnesium oxide may be formed by natural oxidation through which magnesium is heated without artificial gas injection.
[0034] According to another embodiment, there is provided a PDP comprising a protective layer formed of the material. The protective layer may be formed by dispersing the magnesium oxide powder in a solvent to prepare a solution and coating the solution by spin coating, spraying, or printing. Accordingly, the cathode luminescence characteristics of the material are transferred to the protective layer. When a cathode-luminescence spectrum is measured, the protective layer has a first emission peak in a wavelength range of from about 300 to about 370 nm, and a second emission peak in a wavelength range of from about 600 to about 640 nm. An intensity ratio of the first emission peak to the second emission peak may be from about 1:0.40 to about 1:0.60.
[0035] Also, the protective layer can further comprise a third emission peak in a wavelength range of from about 700 to about 800 nm. An intensity ratio of the first emission peak to the third emission peak may be from about 1:0.25 to about 1:0.45.
[0036] A material for forming a protective layer and a method of preparing the material according to the present embodiments will now be explained.
[0037] Magnesium (Mg) in the form of granules or chips is heated in the air to generate vapor. The magnesium may be heated by a heating method, such as torch heating, resistance heating, or high frequency induction heating, in the air or in a gas atmosphere containing air and inert gas. When the vapor reacts with the air and is naturally oxidized, a magnesium oxide is produced. When the magnesium is heated to a temperature over a predetermined level, the magnesium ignites to generate vapor. The generated vapor reacts with the air to prepare a magnesium oxide powder that is thermodynamically stable.
[0038] When a cathode-luminescence spectrum is measured, the magnesium oxide powder has a first emission peak in a wavelength range of from about 300 to about 370 nm, and a second emission peak in a wavelength range of from about 600 to about 640 nm. An intensity ratio of the first emission peak to the second emission peak of the magnesium oxide powder may be from about 1:0.40 to about 1:0.60. Also, the magnesium oxide powder further comprises a third emission peak in a wavelength range of from about 700 to about 800 nm. An intensity ratio of the first emission peak to the third emission peak of the magnesium oxide powder may be from about 1:0.25 to about 1:0.45.
[0039] Also, the magnesium oxide powder has a maximum intensity from about 0.5 to about 10 times higher than that of a conventional magnesium oxide thin film having an emission peak in a wavelength range of 380 to 400 nm. Since the conventional magnesium oxide thin film has the emission peak in the wavelength range of 380 to 400 nm, the conventional magnesium oxide thin film has defects called F+ centers in which a single electron is trapped by an oxygen vacancy. Accordingly, the conventional magnesium oxide thin film has the F+ centers, and the maximum intensity of the emission peak of the oxide magnesium powder according to the present embodiments is from about 0.5 to about 10 times higher than that of the conventional magnesium oxide thin film. The maximum intensity of the emission peak of the magnesium oxide powder according to the present embodiments in the wavelength range of from about 300 to about 370 nm is from 0.5 to about 10 times higher than the maximum intensity of the emission peak of the conventional magnesium oxide thin film in the wavelength range of 380 to 400 nm. Since the emission peak having a maximum intensity of the magnesium oxide powder according to the present embodiments is not in the wavelength range of 380 to 400 nm, the magnesium oxide powder does not have the defects. Here, the magnesium oxide thin film is a polycrystalline magnesium oxide thin film prepared by a deposition method, such as electron beam (e-beam) deposition or ion-plating, using a single-crystalline magnesium oxide pellet or a polycrystalline magnesium oxide sintered body as a source. However, the magnesium oxide powder according to the present embodiments does not have the defects called F+ centers since the emission peak of the magnesium oxide powder is not in the wavelength range of 380 to 400 nm. The maximum intensity of the emission peak of the magnesium oxide powder according to the present embodiments is about 1/1000 as high as that of a magnesium oxide powder that is oxidized by artificially injecting a gas. Since the magnesium oxide powder according to the present embodiments is naturally oxidized, the magnesium oxide powder has little external restriction and is thermodynamically stable, thereby resulting in relatively few defects.
[0040] In addition, since a melting point and a boiling point of magnesium at an atmospheric pressure are respectively as low as about 922 K and about 1364 K, respectively when the magnesium oxide powder according to the present embodiments is prepared, most of other metals that are considered as impurities do not generate vapor, thereby making it possible to produce a high purity magnesium oxide. The high purity magnesium oxide powder may contain at least one impurity of nickel (Ni), iron (Fe), barium (B), silicon (Si), manganese (Mn), chrome (Cr), calcium (Ca), copper (Cu), zirconium (Zr), aluminum (Al), and sodium (Na) in an amount less than about 2 ppm by weight based on the total weight of the magnesium oxide powder.
[0041] A PDP including a protective layer formed of the material will now be explained with reference to FIGS. 1 and 2 .
[0042] Referring to FIGS. 1 and 2 , the PDP includes a front panel 100 through which light is emitted to the outside of the PDP, and a rear panel 200 on which phosphors are disposed to emit light.
[0043] Regarding the front panel 100 , a plurality of transparent electrodes 120 are disposed on a front glass substrate 110 to extend in an X direction, and bus electrodes 130 are disposed on the transparent electrodes 10 in parallel to the transparent electrodes 120 . A front dielectric layer 140 and a protective layer 150 are sequentially stacked on the front glass substrate 110 to cover the transparent electrodes 120 and the bus electrodes 130 . The front dielectric layer 140 may protect the transparent electrodes 120 and the bus electrodes 130 from direct collisions with charged particles participating in a discharge. The front dielectric layer 140 may be protected by the protective layer 150 .
[0044] The protective layer 150 may include a first protective layer 151 and a second protective layer 153 . The first protective layer 151 is a polycrystalline magnesium oxide thin film prepared by e-beam deposition or ion-plating using a magnesium oxide sintered body as a source. The magnesium oxide sintered body is formed by sintering a magnesium oxide powder that may be prepared by precipitation, general vapor deposition, or specific vapor deposition according to the present embodiments.
[0045] The second protective layer 153 is formed by dispersing the magnesium oxide powder prepared as described above in a solvent to prepare a solution and coating the solution by spin coating, spraying, or printing on the first protective layer 151 . The solution may include various additives such as a disperser, a surfactant, or an anti-oxidant as well as the solvent.
[0046] Since the second protective layer 153 is formed by coating the magnesium oxide powder on the first protective layer 151 , the characteristics of the magnesium oxide powder are transferred to the second protective layer 153 . That is, when a cathode luminescence spectrum is measured, the second protective layer 153 may have a first emission peak in a wavelength range of from about 300 to about 370 nm, and a second emission peak in a wavelength range of from about 600 to about 640 nm. Also, the second protective layer 153 further comprises a third emission peak in a wavelength of from about 700 to about 800 nm. An intensity ratio of the first emission peak to the second emission peak of the second protective layer 153 may be from about 1:0.40 to about 1:0.60. Also, an intensity ratio of the first emission peak to the third emission peak of the second protective layer 153 may be from about 1:0.25 to about 1:0.45. By contrast, the first protective layer 151 has an emission peak in a wavelength range of from about 380 to about 400 nm, and has F+ centers. Even though the second protective layer 153 has F+ centers, the F+ centers of the second protective layer 153 are less than the F+ centers of the first protective layer 151 . Also, the second protective layer 153 has a maximum intensity 0.5 to 10 times higher than that of the first protective layer 151 . The first protective layer 151 corresponds to the magnesium oxide thin film. Since the magnesium oxide thin film is transferred to the first protective layer 151 , the cathode luminescence spectrum and defect characteristics of the first protective layer 151 corresponds to those of the magnesium oxide thin film.
[0047] Although the second protective layer 153 may cover 100% of a top surface of the first protective layer 151 , the present embodiments are not limited thereto and the second protective layer 153 may cover only 1% or more of the top surface of the first protective layer 151 for the purpose of transmittance improvement. Also, although the second protective layer 153 may be irregularly formed on the first protective layer 151 , the present embodiments are not limited thereto and the second protective layer 153 may be formed by patterning or inkjet printing to have a predetermined pattern. The second protective layer 153 may be formed on the first protective layer 151 to correspond to barrier ribs 240 and the bus electrodes 130 that are covered during a discharge so as not to emit light to the outside of the PDP.
[0048] Although the protective layer 150 has a double-layer structure including the first protective layer 151 and the second protective layer 153 in FIGS. 1 and 2 , the present embodiments are not limited thereto and the protective layer 150 may include only the second protective layer 153 . In order to improve productivity, the first protective layer 151 , which can easily cover the front dielectric layer 140 , may be first formed and then the second protective layer 153 may be formed on the first protective layer 151 to form the protective layer 150 .
[0049] Regarding the rear panel 200 , a plurality of address electrodes 220 are disposed on a rear glass substrate 210 to extend in a Y direction. A rear dielectric layer 230 is disposed to cover the address electrodes 220 , and the barrier ribs 240 are formed to divide a discharge space into a plurality of discharge cells Ce. Phosphor layers 250 are disposed in the discharge cells Ce. The phosphor layers 250 are disposed on sidewalls of the barrier ribs 240 and on the rear dielectric layer 230 . In detail, the phosphor layers 250 may be respectively disposed in the plurality of discharge cells Ce. In more detail, red phosphor layers, green phosphor layers, and blue phosphor layers may be respectively disposed in the discharge cells Ce. A discharge gas is injected as an ultraviolet ray source into the discharge cells Ce. The discharge gas may be a multi-component gas including xenon (Xe), krypton (Kr), helium (He), and neon (Ne) at a predetermined volume ratio such that ultraviolet rays are radiated to excite the phosphor layers 250 . In particular, the second protective layer 153 can significantly reduce a firing voltage and a sustain voltage even under a discharge gas atmosphere containing 50% by volume of xenon (Xe). Accordingly, a discharge gas containing a large amount of xenon (Xe), for example, 10% or more by volume based on the total volume of the discharge gas, may be used. The discharge gas containing the large amount of xenon (Xe) has high luminous efficiency, but there is a limitation in practically using the discharge gas containing the large amount of xenon (Xe) because a high firing voltage is required, a driving voltage and power consumption are increased, and a circuit for increasing rated power needs to be redesigned. However, since the protective layer according to the present embodiments can reduce a firing voltage and a sustain voltage, the drawback of the discharge gas containing the large amount of xenon (Xe) can be overcome.
[0050] Referring to FIG. 2 , each of the discharge cells Ce forms an independent area from an adjacent discharge cell due to the barrier ribs 240 . In detail, the discharge cells Ce include sustain electrode pairs X and Y and address electrodes 220 extending in a direction perpendicular to the sustain electrode pairs X and Y. Each of the sustain electrode pairs X and Y includes an X electrode X and a Y electrode Y. The X electrode X includes an X transparent electrode 120 X and an X bus electrode 130 X, and the Y electrode Y includes a Y transparent electrode 120 Y and a Y bus electrode 130 Y. A voltage is alternately applied to the sustain electrode pairs X and Y to generate a display discharge. Prior to the display discharge, an address discharge is generated between the Y electrode Y and the address electrodes 220 . The address discharge enables priming particles to be accumulated in a discharge cell Ce to be displayed to generate a display discharge and emit light to the outside of the PDP.
[0051] An embodiment, comparative examples, and a contrastive example for the material for forming the protective layer, and evaluations of the embodiment, the comparative examples, and the contrast example will now be explained in detail.
EMBODIMENT FOR MATERIAL FOR PROTECTIVE LAYER
Magnesium Oxide Powder A
[0052] 1 g of magnesium in the form of a pellet was burnt for 15 seconds in a propane-oxygen flame. The propane-oxygen flame was ignited at a temperature of 700 to 900° C. and the magnesium was heated to a temperature of 2300 to 3300° C. to generate vapor. The vapor was collected to produce a magnesium oxide powder A. Here, the magnesium was heated in an atmospheric environment containing no inert gas and no artificial gas.
COMPARATIVE EXAMPLE 1 FOR MATERIAL FOR PROTECTIVE LAYER
Magnesium Oxide Powder B
[0053] A magnesium oxide powder B was prepared by precipitation. Magnesium ions dissolved in seawater was precipitated as a magnesium hydroxide by using caustic soda, calcium hydroxide, and calcined dolomite. That is, the magnesium hydroxide was obtained by a reaction represented by Chemical Formula 1, and was thermally treated at a temperature of 500° C. or more to obtain the magnesium oxide powder B by a reaction represented by Chemical Formula 2.
[0000] MgCl 2 +2NaOH=Mg(OH) 2 +2NaCl (1)
[0000] Mg(OH) 2 →MgO+H 2 O (2)
COMPARATIVE EXAMPLE 2 FOR MATERIAL FOR PROTECTIVE LAYER
Magnesium Oxide Powder C
[0054] 1 g of magnesium was subjected to resistance heating in a chamber to generate magnesium vapor. Oxygen (O 2 ) and argon (Ar) were added to the magnesium vapor at flow rates of 2 liters/min and 5 liters/min, respectively, to prepare a magnesium oxide powder C.
COMPARATIVE EXAMPLE 3 FOR MATERIAL FOR PROTECTIVE LAYER
Magnesium Oxide Powder D
[0055] A magnesium oxide powder D was prepared in the same way as for Comparative Example 2 for the material for forming the protective layer except that oxygen (O 2 ) and argon (Ar) were added to a magnesium vapor at flow rates of 10 liters/min and 1 liter/min, respectively.
CONTRASTIVE EXAMPLE
Polycrystalline Magnesium Oxide Thin Film D
[0056] A polycrystalline magnesium oxide thin film E was prepared to a thickness of 7000 Å on a dielectric layer by e-beam deposition using 100 g of polycrystalline magnesium oxide pellet as a source. The polycrystalline magnesium oxide pellet was prepared by sintering the magnesium oxide powder B of the Comparative Example 1.
Evaluation 1
Cathode Luminescence Spectrum
[0057] The cathode luminescence characteristics of the magnesium oxide powders A, B, C, and D of Embodiment and Comparative Examples and the polycrystalline magnesium oxide thin film E of Contrastive Example were evaluated.
[0058] Each of the magnesium oxide powders A, B, C, and D was pressed to prepare a pellet. The pellet was prepared to have a surface-to-volume ratio of 90 to 95%. The cathode luminescence characteristics of the pellets of the magnesium oxide powders A, B, C, and D were measured by accelerating and focusing electron beams of 5 keV. The cathode luminescence characteristics of the polycrystalline magnesium oxide thin film E of Contrastive Example were also measured by accelerating and focusing electron beams of 5 keV. A used electron beam source was a Ta disc, EGPS-3101C, made by Kimball Physics, and a spot size during collisions between the electron beams and the pellets was approximately 1 mm. Also, a used spectrometer was SpectraPro 2500i made by Action, and intensity was to calculate a sum of intensities measured in 300, 500, and 750 gratings/mm.
[0059] Referring to FIG. 3A , the magnesium oxide powder A of Embodiment had an emission peak in a wavelength range of 300 to 500 nm. In detail, the magnesium oxide powder A had an emission peak in a wavelength range of 300 to 370 nm, a second emission peak in a wavelength range of 600 to 640 nm, and a third emission peak in a wavelength range of 700 to 800 nm. An intensity ratio of the emission peak to the second emission peak to the third emission peak was approximately 1:0.52:0.37. The intensity of the emission peak was 300 counts/sec.
[0060] The magnesium oxide powder B prepared by precipitation had an emission peak having an maximum intensity in a wavelength range of 300 to 450 nm and an emission peak having a second highest intensity in a wavelength range of 650 to 750 nm. The maximum intensity of the emission peak was approximately 800 counts/sec.
[0061] The polycrystalline magnesium oxide thin film E of Contrastive Example had an emission peak having an maximum intensity in a wavelength range of 350 to 450 nm and an emission peak having a second highest intensity in a wavelength range of 650 to 750 nm.
[0062] Referring to FIG. 3B , the magnesium oxide powders C and D prepared by other vapor depositions had emission peaks in wavelengths of approximately 200 nm to approximately 250 nm, approximately 450 nm to approximately 500 nm, and approximately 650 nm to approximately 750 nm. The maximum intensities of the emission peaks of the magnesium oxide powders C and D were 90000 and 40000 counts/sec, respectively.
[0063] Accordingly, since the magnesium oxide powder A of Embodiment according to the present embodiments had a spectrum different from those of the magnesium oxide powders B, C, and D and the polycrystalline magnesium oxide thin film E, the magnesium oxide powder A of Embodiment had defects different from the those of the magnesium oxide powders B, C, and D and the polycrystalline magnesium oxide thin film E. Also, since the maximum intensity of the emission peak of the magnesium oxide powder A of Embodiment was much lower than those of the magnesium oxide powders B, C, and D, the magnesium oxide powder A of Embodiment had fewer defects than those of the magnesium oxide powders B, C, and D. That is, the magnesium oxide powder A of Embodiment had superior crystalline characteristics.
Evaluation 2
[0064] An inductive coupled plasma (ICP) analysis was performed on 5 g of each of the magnesium oxide powders A, B, C, and D and results of the ICP analysis are shown in Table 1. In Table 1, ND denotes non-detected.
[0000]
TABLE 1
(ppm)
Ni
Fe
B
Si
Mn
Cr
Ca
Cu
Zr
Al
Na
A
ND
ND
ND
ND
ND
<1.0
ND
ND
ND
ND
ND
B
ND
1.5
ND
<1.0
<1.0
<1.0
9.1
<1.0
ND
ND
155
C
ND
ND
ND
ND
2.4
<1.0
ND
ND
ND
ND
4.1
D
ND
ND
ND
ND
11
<1.0
6.8
ND
ND
ND
ND
[0065] Referring to Table 1, the magnesium oxide powder A of Embodiment had fewer impurities than the magnesium oxide powders B, C, and D of Comparative Examples. In detail, 5 g of the magnesium oxide powder A of Embodiment contained 1.0 ppm impurities, and 5 g of the magnesium oxide powders B, C, and D of Comparative Examples had approximately 168.6, 7.5, and 18.8 ppm impurities, respectively.
[0066] An embodiment, comparative examples, and evaluations for the protective layer of the PDP formed by using the aforementioned material will now be explained in detail.
EMBODIMENT FOR PROTECTIVE LAYER OF PDP
Protective Layer A
[0067] After a disk type silver (Ag) electrode that generates an opposed discharge and has a diameter of 8 mm was formed on a substrate that was PD200 made by Asahi, a lead oxide (PbO)-based dielectric layer was formed to a thickness of approximately 35 μm on the electrode. A first protective layer was formed on the dielectric layer to a thickness of 700 nm by e-beam deposition using a polycrystalline magnesium oxide source.
[0068] 300 mg of the magnesium oxide powder A of Embodiment was mixed with 5 ml of absolute alcohol to prepare a solution, and the solution was coated by spin coating on the first protective layer to a thickness of 1 μm to form a second protective layer.
COMPARATIVE EXAMPLE 1 FOR PROTECTIVE LAYER OF PDP
Protective Layer B
[0069] A protective layer was prepared in the same way as for the protective layer of Embodiment except that the magnesium oxide powder B of Comparative Example 1 instead of the magnesium oxide powder A of Embodiment and spin coating were used.
COMPARATIVE EXAMPLE 2 FOR PROTECTIVE LAYER OF PDP
Protective Layer C
[0070] A protective layer was prepared in the same way as for the protective layer of Embodiment except that the magnesium oxide powder C of Comparative Example 2 instead of the magnesium oxide powder A of Embodiment and spin coating were used.
COMPARATIVE EXAMPLE 3 OF PROTECTIVE LAYER OF PDP
Protective Layer D
[0071] A protective layer was prepared in the same way as for the protective layer of Embodiment except that the magnesium oxide powder D of Comparative Example 3 instead of the magnesium oxide powder A of Embodiment and spin coating were used.
Evaluation 3
[0072] FIGS. 4A and 4B are scanning electron microscopic (SEM) images of a surface of the protective layer of Embodiment. FIG. 4A is an SEM image taken at 500-times magnification and FIG. 4B is an SEM image taken at 100,000-times magnification.
[0073] Referring to FIG. 4B , a plurality of single crystalline magnesium oxide particles aggregate. The single crystalline magnesium oxide particles have sizes of 100 to 500 nm which are substantially uniform.
Evaluation 4
[0074] A firing voltage and a sustain voltage of each of the protective layers A to D of Embodiment and Comparative Examples were measured using a singe wave of 2 kHz under a discharge gas atmosphere containing 15% by volume of xenon (Xe) and 85% by volume of neon (Ne). A firing voltage and a sustain voltage of the polycrystalline magnesium oxide thin film E of Contrastive Example were also measured using a singe wave of 2 kHz under a discharge gas atmosphere containing 15% by volume of xenon (Xe) and 85% by volume of neon (Ne).
[0075] Referring to FIG. 5A illustrating a firing voltage and FIG. 5B illustrating a sustain voltage, a firing voltage and a sustain voltage of the protective layer A were much lower than those of the protective layer B and the protective layers C and D. In detail, the firing voltage and the sustain voltage of the protective layer A were approximately 35% lower than those of the polycrystalline magnesium oxide thin film E of Contrastive Example.
Evaluation 5
[0076] A firing voltage and a sustain voltage were measured after the content of xenon was increased. A firing voltage and a sustain voltage were measured, in the same way as for Evaluation 4, under a discharge gas atmosphere containing 50% by volume of xenon (Xe) and 50% by volume of neon (Ne).
[0077] Referring to FIGS. 6A and 6B , the firing voltage and the sustain voltage of the protective layer A were much lower than those of the protective layers B, C, and D, and were approximately 35% lower than those of the polycrystalline magnesium oxide thin film E of Contrastive Example.
[0078] Furthermore, even after the content of xenon (Xe) was increased up to 50% by volume, the firing voltage and the sustain voltage of the protective layer A were much lower than those of the polycrystalline magnesium oxide thin film E of Contrastive Example which contains 15% by volume of xenon (Xe), thereby improving discharge efficiency and ensuring stable operation.
Evaluation 6
[0079] The light emission characteristics of the protective layers A to D of Embodiment, Comparative Examples, and Contrastive Example were evaluated.
[0080] In detail, a sample of each protective layer which has a size of 2×2.5 cm was prepared, a surface of the sample was scanned at a temperature 300° C. for 240 minutes at 1 keV by using Ar+ ions in order to activate and clean the surface of the sample and was excited by a 254 nm ultraviolet (UV) source, and the quantity of electrons emitted from the sample was measured by using an electron detector at a height of about 1 to 2 cm over the sample.
[0081] Referring to FIG. 7 , the protective layer A had much higher light emission characteristics than the protective layers B, C, and D of Comparative Examples.
[0082] Accordingly, during a real discharge, a discharge voltage can be reduced by increasing a value γ effective . The value γ effective may be defined by
[0000] γ effective =γ ion +γ metastable +γ photon +γ exo + . . . (1).
[0083] As shown in Mathematical Formula 1, effective secondary electron emission in a discharge space may be determined not only by potential emission due to ions but also by secondary electron emission due to excited spices, photons, and exo-emission,
Evaluation 7
[0084] The quantity of secondary electrons emitted for approximately 300 seconds after the supply of a discharge voltage was cut off was measured.
[0085] A sample of each protective layer which has a size of 2×2.5 cm was prepared and was excited for 5 minutes by using a 160 nm vacuum ultraviolet (VUV) source, and the quantity of electrons emitted from the sample was measured by using the electron detector at a height of about 1 to 2 cm over the sample in 5 seconds after the VUV source was removed.
[0086] Referring to FIG. 8 , the protective layer A had much higher light emission characteristics even after the supply of the discharge voltage was cut off than those of the protective layers B, C, and D of Comparative Examples. Furthermore, the exo-emission characteristics of the protective layer A were hundred to thousand times higher than those of the polycrystalline magnesium oxide thin film E of Contrastive Example.
[0087] The quantity of electrons reduced over time of the protective layer A was also lower than those of the protective layers B, C, and D and the polycrystalline magnesium oxide thin film E of Contrastive Example. The protective layer A showed first order exponential decay.
[0088] The protective layer A of conducted electrons in the vicinity of a conduction band, and in the protective layer A, only basic electron traps existed and electrons remaining in traps were recombined with holes after excitation. However, in the protective layers C and D, not only electron traps but also recombination centers of various mechanisms existed, thereby increasing a cathode luminescence intensity and causing different electron emission reductions. The large quantity of electrons emitted from the protective layer A reduced a discharge delay time during a subsequent discharge and increased the value γ effective in a photo-emission to reduce a discharge voltage.
[0089] As described above, the protective layer formed of the material prepared by specific vapor deposition according to the present embodiments is a single crystalline protective layer that contains an extremely small quantity of impurities, is thermodynamically stable, has few defects, and also has a high value γ effective due to high photon emission and exo-electron emission. Accordingly, the protective layer according to the present embodiments can remarkably reduce a firing voltage and a sustain voltage. Hence, the protective layer according to the present embodiments can considerably improve discharge efficiency by increasing the content of xenon (Xe) that is most challenging in the study of PDPs.
[0090] While the present embodiments have been particularly shown and described with reference to exemplary embodiments thereof it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present embodiments as defined by the following claims.
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Disclosed is a material for forming a protective layer, a protective layer employing the material and a PDP with the protective layer. Unlike conventional protective layers which employ MgO created in conditions of pressurized artificial gas, the instant protective layer uses MgO created by heating Mg and allowing it to oxidize naturally in air. The result is MgO with fewer defects that is more effective as a protective layer in many uses, such as in a PDP. The instant MgO also shows many specific spectral characteristics and contains impurities in amounts of less than about 2 ppm each. Also disclosed is a PDP which takes advantage of the advantages of the inventive protective layer.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to water-soluble quaternary ammonium vinyl monomers, to cationic water-soluble homopolymers and copolymers of these monomers with acrylamide and other compounds, to a vinyl compound specially useful for production of the aforesaid quaternary ammonium monomers, to paper of improved dry strength resulting from a content of the aforesaid copolymers, and to the various methods involved in making the foregoing products.
Dry strength paper is a specialty of the papermaker's art. It is paper which possesses excellent tensile strength when dry but which possesses substantially no tensile strength when wet. Dry strength paper rapidly disintegrates when allowed to fall into a natural environment and so solves an ecological problem.
There is also a demand for a cationic polymer which provides only dry strength, but which can be made to provide wet strength as well by an inexpensive and easy modification.
At the present time, dry strength paper is manufactured on a large commercial scale by adding a water-soluble anionic polymer to an aqueous suspension of cellulose papermaking fibers, precipitating the polymer on the fibers by the action of alum, forming the fibers into a web and drying the web; cf. Canadian Pat. No. 477,265. A disadvantage of the process is that the papermaking system throughout the operation is at an acid pH with resulting corrosion of the papermaking machine. A further disadvantage is that the paper which it produces is acid and undergoes acid tendering as it ages. An additional disadvantage is that the sulfate ions (introduced as part of the alum) are not adsorbed by the cellulose and so accumulate in the aqueous phase of the system, creating a disposal problem. Moreover, anionic polymers are poorly effective in papermaking systems which contain black liquor solids, so that for best results the pulps must be well washed. Water of sufficient purity for pulp washing is now a critical commodity in many paper mills.
2. Description of the Prior Art
It has long been known that the water-soluble vinyl cationic polymers which are composed of acrylamide units in predominant proportion and of vinyl quaternary ammonium units in minor proportion are good dry strengthening agents when added to the aqueous cellulose fiber suspensions from which paper is made (cf. Wilson et al. U.S. Pat. Nos. 2,884,057; 2,884,058; and Moore, U.S. Pat. No. 3,077,430) even in the absence of alum, at alkaline pH values up to at least pH 10; that they are effective at acid pH values at least down to pH 4; and that they are not sensitive to dissolved sulfate ions (at least in moderate amount). These polymers therefore possess major practical advantages.
A disadvantage of the polymers of the aforesaid patents is that they are difficult and costly to make, so that they are uneconomic. Accordingly, attempts to introduce these polymers into the commercial manufacture of paper have not proved successful.
SUMMARY OF THE INVENTION
The discovery has now been made that benefits indicated above can be attained in an economic way be starting with a water-soluble N-(chloro C 2 -C 5 alkoxymethyl)acrylamide represented by the formula C 2 ##EQU1## wherein A represents a C 2 -C 5 alkyl substituent as precursor of the cationic component. I have found that this compound is simple and cheap to make, and that highly effective cationic dry strengthening polymers can be made either by quaternizing the compound with a suitable water-soluble amine and then copolymerizing the product with acrylamide or by performing the copolymerization first and then quaternizing the resulting polymer. The quaternized monomers have the theoretical formula: ##EQU2## wherein "C 2 -C 5 alkylene" designates a hydrocarbon group, for example --CH 2 CH 2 --, --CH(CH 3 )--CH 2 -- and CH 2 CH 2 CH 2 CH 2 --, and Q designates the residue of a water-soluble tertiary amine (i.e., a hydrophilic quaternary ammonium group). The substituents retain their structure when the monomers are subjected to vinyl polymerization.
I have found that the water-soluble cationic polymers composed of acrylamide units in preponderant proportion and the above-described vinyl quaternary ammonium units in minor proportion are cheaply and easily prepared, and possess the following beneficial properties: they are storage-stable at acid, neutral and alkaline pH values; they are strongly cationic excellent dry strength agents which are suitable for use as beater or "wet end" additives in the manufacture of paper, and they are effective for this purpose in the principal pulps and water systems employed in modern paper manufacture.
A particular advantage of these polymers is that they do not require the presence of alum or other precipitating agent for their utility, and they provide excellent dry strengthening in the prevalent acidic pH range (4-6) as well as in the alkaline pH range (8-12) needed for production of paper which contains alkaline filler material. Since they are not sensitive to dissolved sulfate ions, they can be used in systems which have been previously used for the manufacture of rosin sized paper.
A surprising property of the N-(chloro C 2 -C 5 alkoxymethyl) acrylamides in polymerized or unpolymerized state is the stability of their ether linkages. It might be expected that this linkage would hydrolyze easily at moderate conditions of pH and temperature, either before or after the quaternization reaction, as is more particularly hereinafter disclosed. It also might be expected that this linkage would transamidate easily. However, I have found that this and the other two principal linkages in the compound (the amide and quaternary ammonium linkages) are all adequately stable over the broad pH range from 3 to 12 to permit aqueous solutions of the polymer to be shipped and consumed in accordance with commercial practice.
I have also found that the vinyl double bond is strongly resistant to uncatalyzed addition reactions, but undergoes normal vinyl polymerization at any pH in the range of 3-10 without substantial decomposition. As a result, the compound has broad utility as a comonomer capable of providing cationic sites in vinyl polymerization.
I have finally found that the compound, before or after vinyl polymerization, quaternizes readily with any water-soluble tertiary amine, a feature which provides it with unusual technical flexibility.
More in detail, according to the invention, the preferred starting materials, namely, the N-chloro C 2 -C 5 alkoxymethyl)-acrylamides, are prepared by reacting a C 2 -C 5 chloroalkanol with N-(hydroxymethyl)acrylamide (made by reacting acrylamide with formaldehyde).
Taking 2-chloro-1-ethanol as an example of the chloroalkanol, the reaction proceeds as follows: ##EQU3## I have found that high yields of the desired product are obtained at 60°C. (without need for pressure equipment) when 2-chloro-1-ethanol is present in excess and the reaction mixture is maintained at a highly acid pH (below about 2). The reaction is substantially complete in 1 hour, after which the excess chloroethanol can be recovered by distillation under vacuum, and the ionic chloride which forms can be recovered by addition of sodium bicarbonate; the chloride precipitates as sodium chloride and can be filtered off. The residue is a tan liquid, N-(2-chloroethoxymethyl)acrylamide.
These products are soluble in cold (or, if necessary, hot) water.
For this reaction, any of the C 2 -C 5 chloroalkanols can be used, including 2-chloro-1-ethanol (also known as ethylene chlorohydrin), 3-chloro-1-propanol (also known as trimethylene α-chlorohydrin), and 3-chloro-amyl alcohol (3-chloro-1-pentanol). The corresponding bromo compounds are chemical equivalents and can also be used. In practice I prefer to use 2-chloro-1-ethanol because this compound is commercially available at low cost and has a lower boiling point than the other compounds mentioned, which facilitates recycling of any excess present.
The dry strengthening polymers of the present invention can be prepared by two different procedures.
According to the first procedure, a N-(chloro-C 2 -C 5 -alkoxy-methyl)acrylamide is quaternized in any convenient manner and the resulting acrylamidomethoxyalkyl quaternary is then subjected to a vinyl polymerization with acrylamide or with methacrylamide (a functional equivalent). In this procedure, the quaternization reaction is conveniently performed by dissolving the 1 mol of the N-substituted acrylamide and between 0.5 and 1.5 mol of a water-soluble tertiary amine in about the minimum amount of water needed for the purpose, and heating the solution slowly (e.g., over 3 hours) from 30°C. to 95°C. Any excess amine present can be recovered by distillation or a selective solvent. The product need not be recovered in dry form, but if desired, the water can be removed by vacuum or azeotropic distillation or by use of anhydrous methanol.
According to the second method, the N-substituted acrylamide is first copolymerized with the unsubstituted acrylamide and the pendant chloro (or bromo) substituents are then quaternized as described above. This method is not preferred because the copolymerization reaction is generally performed in dilute aqueous solution, and a larger excess of the tertiary amine generally must be used, or a large amount of water must be removed.
For the quaternization reaction any water-soluble tertiary amine can be used. Suitable amines of this class include trimethylamine, tripropylamine, pyridine, the picolines, decahydroquinoline, N-methylmorpholine, triethanolamine, dimethyl 2-hydroxyethyl amine, and N,N-diethylaniline, although they quaternize at different speeds. Trimethylamine is preferred for the purpose because it is readily available at low cost, because its molecular weight is low, because it is stable, and because any unreacted excess of the material can be easily recovered by distillation after the quaterizaton.
The quaternized N-(chloroC.sub. 2 -C 5 alkyloxymethyl)acrylamide can be polymerized with acrylamide (or with methacrylamide) by any of the procedures by which acrylamide itself has been homopolymerized in the past. There is no criticality in the particular method which may be selected.
In practice I prefer to perform the copolymerization in aqueous solution in the absence of oxygen using a redox catalyst; cf. U.S. Pat. No. 2,923,701. The product is a sticky hydrous gel which can be dried for shipment by the method of U.S. Pat. 3,634,944.
The reaction is performed by heating the mixture at a temperature in the range of about 40°-100°C. The reaction proceeds unnecessarily slowly below the range, and undesirable side reactions (including imide formation) occur above that range.
The quaternizable acrylamides can also be made by two other methods, both transetherifications.
According to one method, a water-soluble N-(alkoxymethyl)acrylamide (made by reacting N-(hydroxymethyl)acrylamide with ethyl alcohol) and a water-soluble hydroxy(C 2 -C 5 alkyl) di(C 2 -C 5 alkyl)amine are heated together at an acid pH until evolution of alkanol has substantially ceased. Taking dimethyl 2-(hydroxyethyl)amine as an example of the amine, the transetherification proceeds as follows: ##EQU4## where R represents a C 1 -C 12 alkyl and preferably a C 1 -C 4 alkyl group (so that the alcohol formed by the transetherification reaction volatilizes as it is formed). The reaction proceeds very rapidly at 50°-70°C. under vacuum. The product can be quaternized with a C 2 -C 5 alkyl or hydroxyalkyl halide, dimethyl sulfate, or any other convenient quaternizing agent (which provides sulfate, chloride, bromide, iodide etc. counterions).
An advantage of this method is that the 2-chloro-1-ethanol (which is toxic) is not needed, and the 2-hydroxyethyl dialkyl amine need not be used in excess.
If desired, the hydroxyalkyl dialkyl amine can be replaced by a hydroxyalkyl tri(C 2 -C 5 alkyl) ammonium halide with direct production of the acrylamide quaternary.
According to the other method, the transetherification is performed by use of a C 2 -C 5 chloroalkanol. Taking 2-chloro-1-ethanol as an example of the alcohol, it proceeds as follows:
IV. CH.sub.2 =CH-CONHCH.sub.2 OR + HOCH.sub.2 CH.sub.2 Cl .sup.HCl CH.sub.2 =CH-CONHCH.sub.2 OCH.sub.2 CH.sub.2 Cl + ROH
wherein R represents a C 1 -C 12 (and preferably a C 1 -C 4 ) alkyl group. Here again only 1 mol of the chloroalkanol is needed for good yields, and no more than a slight (e.g., 0.1 mol) excess is needed to effect substantially complete transetherification.
If desired, the quaternary may be homopolymerized. The product has a very high cationic density, and is specially useful as a flocculant for suspended solids in water (e.g., sewage solids, colloidal coal particles, ore and clay particles, and cellulose fines).
In general, at least 1 mol percent of quaternary units are needed to render the polymer self-substantive to cellulose under paper-making conditions, and about 5 mol percent is needed to avoid the risk of inefficient performance. On the other hand, more than 10 mol percent of quaternary units is unnecessary to ensure efficient adsorption, and more than about 25 mol percent is often detrimental. Accordingly, the polymers which are intended for use as strengthening agents contain 1 to 25 mol percent of quaternary units (and 99 - 75 mol percent of acrylamide units), whereas the polymers which are preferred for the purpose contain 5 to 10 mol percent of quaternary units (and 95 to 90 mol percent of acrylamide units).
If desired, the polymers may contain minor amounts of other units which act as diluent or spacing units, so long as they do not change the essential water-soluble cationic character of the polymer. Thus the polymer may contain minor amounts of vinylamine, methyl acrylate, vinyl acetate, acrylonitrile, and acrylic acid linkages. The acrylic acid linkages decrease the cationicity of the polymer, but are helpful in that they render the polymer amphoteric and so suitable for use in pulps containing alum and having an acid pH.
The invention is further described in the examples which follow. These examples are preferred embodiments of the invention and are not to be construed in limitation thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
The following illustrates the preparation of a N-(2-chloroalkoxymethyl)acrylamide by a process according to the present invention.
To a solution of 332 g. of 91% N-(hydroxymethyl) acrylamide (3.13 mols) in 1640 g. (20.4 mols) of 2-chloroethanol in a reaction flask equipped with thermometer, stirrer, dropping funnel and distillation head is added sufficient (about 3 ml.) of 20 N H 2 SO 4 to decrease the pH of the solution below 0.5. The solution is heated at 60°C. for 1 hour, cooled to room temperature and adjusted to pH 8 with 10% aqueous NaOH. The reaction mixture is then filtered to remove the sodium chloride which forms. The filtrate is returned to the reaction vessel. There are then added 0.025 g. of phenothiazine as free radical inhibitor, 0.05 g. of the methyl ether of hydroquinone as polymerization inhibitor, and 2 g. of NaHCO 3 as stabilizer, to provide a pH of about 8. The water and excess 2-chloroethanol are removed by distillation first at 54°C. to 60°C. under a vacuum of 28 to 28.8 inches and then at 80°C. under a vacuum of 4 mm. of mercury. The product is then filtered. It is substantially pure N-(2-chloroethoxymethyl)-acrylamide, and is a clear faintly yellow oil.
The product is adjusted to pH 7 and stored in a dark stoppered bottle at -20°C. to inhibit decomposition. It is substantially unchanged after a month.
Example 2
The procedure of Example 1 is repeated except that 1900 g. of 3-chloro-1-propanol is used in place of the 2-chloro-1-ethanol. N-(3-Chloropropoxymethyl)acrylamide is obtained.
Example 3
The following illustrates the preparation of a N-(2-chloroalkoxymethyl)acrylamide by a transetherification reaction.
To a mixture of 115 g. (1 mol) of N-(methoxymethyl)acrylamide and 160 g. (2 mols) of peroxide-free 2-chloroethanol in a flask set up for vacuum distillation is added 1.5 ml. of 25% aqueous hydrochloric acid. Vacuum is applied. The mixture is slowly heated at 60°C. (over 30 minutes) and the vacuum is increased to 4 mm. over this period of time. The temperature is then raised to 80°C. with continuation of the vacuum to strip off the excess chloroethanol and the methanol which is formed by the reaction.
Example 4
The following illustrates the preparation of a water-soluble quaternary ammonium monomeric derivative of a N-(2-chloroalkoxymethyl)acrylamide.
In a three-necked flask equipped with stirrer, thermometer and reflux condenser, a mixture of 302 g. of 30% aqueous trimethylamine (1.54 mol) and 232 g. (1.54 mol) of the N-(2=chloroethoxymethyl)acrylamide of Example 1 is heated to 30°C. and is maintained at that temperature for 1 hour, a dry ice-acetone mixture being applied in the condenser as needed to control the exotherm which develops. The water present is about the minimum amount which is needed to dissolve the reagents and the product. The mixture is then heated at 55°-65°C. for 1 hour, at 87°C. for 30 minutes, and at 93°-95°C. for 10 minutes. The resulting alkaline solution is then cooled and its pH adjusted to 7 by addition of 10% aqueous hydrochloric acid. The water and any residual trimethylamine are removed by distillation under a vacuum of 4 mm. of mercury. The product is 2-(acrylamidomethyoxy)ethyl trimethyl ammonium chloride having the theoretical formula: ##EQU5##
Example 5
The procedure of Example 4 is repeated, except that the trimethylamine solution is replaced by 158 g. of 2-(dimethylamino)ethanol in 250 cc. of ater [2-(Acrylamidomethoxy)ethyl]dimethyl ethanol ammonium chloride is formed.
Example 6
The procedure of Example 4 is repeated except that the trimethylamine solution is replaced by 156 g. of N-methylmorpholine dissolved in 250 g. of water. 2-(Acrylamidomethoxy) ethyl methyl morpholinium chloride is obtained.
Example 7
The following illustrates the preparation of a copolymer consisting essentially of N-2(acrylamidomethoxy) ethyl trimethyl ammonium chloride and acrylamide linkages or units which is effective as dry strengthening agent, prepared by a method wherein the polymerization step is performed after the quaternization step.
An aqueous solution of 20 g. (0.0895 mol) of (2-acrylamidomethoxy)ethyl trimethyl ammonium chloride (prepared by the method of Example 4), 30 g. (0.739 mol) of acrylamide, and 0.2 g. of azobisisobutyronitrile in 520 g. of deoxygenated water is heated under a nitrogen blanket for 3 hours at 40°-55°C., at which time the reaction is substantially complete.
Example 8
The procedure of Example 7 is repeated except that the vinyl quaternary monomer is replaced by 140 g. of the vinyl quaternary monomer of Example 5. A similar polymer is obtained.
Example 9
The procedure of Example 7 is repeated except that the vinyl quaternary monomer is replaced by 78.5 g. of the vinyl quaternary monomer of Example 5. The resulting pyridinium polymer is about as effective as flocculant as the polymer of Example 6.
Example 10
The procedure of Example 7 is repeated except that the vinyl quaternary monomer is replaced with 24 g. of the vinyl quaternary monomer of Example 6. A similar polymer is obtained.
Example 11
The following illustrates the manufacture of a copolymer according to the present invention by a process wherein the quaternization step is performed after the vinyl polymerization step.
A reaction flask fitted with stirrer, thermometer, dropping funnel and gas inlet tube is flushed out with nitrogen, and into the flask are placed under nitrogen 10 g. (0.06 mol) of N-(2-chloroethoxymethyl)acrylamide, 40 g. (0.57 mol) of acrylamide, 1750 ml. of water and 0.3 g. each of sodium metabisulfite and ammonium persulfate. The solution is heated to 40°C. An exothermic reaction occurs which is controlled at 45°C. by application of cooling. After 1 hour at 40°-45°C. the reaction is substantially complete and the product is a viscous solution composed of the unsubstituted acrylamide and the N-substituted acrylamide in 90.5 : 9.5 molar ratio.
To the solution is added with stirring 79 g. of a 10% by weight aqueous solution of N-propyl morpholine, (0.06 mol and the solution is maintained at 70°C. for 24 hours, at which point quaternization is substantially complete.
The product is an effective strengthening agent for paper when added to beater pulp at pH 8 in amount equal to 0.3% of the dry weight of the fibers.
Example 12
The following illustrates the preparation of a different copolymer according to the present invention starting with an acrylamido tertiary amine, the quaternary ammonium groups being formed as a last step after completion of the polymerization reaction.
To 132 g. of 2-(dimethylamino)ethanol hydrochloride (prepared by neutralizing the free base in isobutyl alcohol solution with concentrated aqueous hydrochloride followed by the addition of benzene and distillation at atmospheric pressure to remove the water by azeotropic distillation and then under vacuum to remove the solvents; in apparatus set for vacuum distillation with the receiver cooled in dry ice-acetone mixture; is added 167 g. (1.02 mol) of N-isobutoxymethyl acrylamide 95% pure containing 200 p.p.m. of methyl ethyl hydroquinone as inhibitor. To the resulting clear solution is added 0.1 g. of potassium iodide and 1.5 ml. of concentrated hydrochloric acid.
The reaction mixture is heated to 70°-75°C. A vacuum of 16 mm. of mercury is applied and a small amount of air is bubbled through the solution to stabilize the distillation and to assist removal of the isobutanol. After 5 minutes the vacuum is increased to 3 mm. and the temperature raised to 80°C. over 10 minutes.
The vacuum is then broken. The weight of distillate is 57 g. To this is added 0.5 ml. of concentrated hydrochloric acid and heating is continued at 80°C. for 15 minutes under a vacuum of 4 mm. An additional 16 g. of distillate is obtained. The total yield is 73 g., equivalent to 95% of the theoretical.
The distillate is a viscous liquid. It is dissolved in 100 cc. of water containing 5 ml. of 10% NaOH. The resulting solution is filtered to remove particles of gel. The filtrate weights 511 g. and contains 38.4% of N-(dimethylaminoethoxymethyl)acrylamide hydrochloride.
Example 13
The following illustrates the preparation of a homopolymer according to the present invention.
The procedure of Example 7 is repeated except that 210 g. (1 mol) of 2-(acrylamidomethoxy)ethyl trimethyl ammonium chloride is used in place of the mixture of monomers of Example 7.
The product is a tan syrup which dissolves readily in water.
Example 14
The polymer product of Example 13 is diluted to 0.1% solids with water, and is added with gentle stirring to aliquots of laboratory stock aqueous suspensions as follows:
Cellulose fines (in white water from papermaking systems).
Colloidal soft coal.
Colloidal argillaceous matter (river mud).
Mine effluent water (colloidal ore slimes).
Sewage sludge suspension.
In each instance the solution is added in amount sufficient to provide 50 parts of the polymer per million parts by weight of the suspension to be clarified. In each instance rapid and substantially complete flocculation occurs with development of a clear phase after settling.
Example 15
The following illustrates the preparation of a vinyl quaternary ammonium compound by transetherification of a lower alkoxy alkyl acrylamide with a non-volatile hydroxyalkyl trialkyl ammonium salt.
A mixture of 70 g. of 2-hydroxyethyl trimethyl ammonium chloride (choline chloride) and (85 g.) of N-(isobutoxymethyl)acrylamide is acidified with 1.5 ml. of hydrochloric acid and 0.1 g. of potassium iodide is added as polymerization inhibitor. The resulting solution is heated to 75°C. under vacuum (16 mm.) and the distillate is collected in a dry ice-acetone trap, a small amount of air being bled in from time to time to stabilize the distillation and to assist removal of the isobutyl alcohol formed. After 5 minutes of heating, the vacuum is increased to 3 mm. and the temperature raised to 80°C. over 10 minutes.
The vacuum is then broken, 0.5 ml. of concentrated hydrochloric acid is added and heating at 80°C. is continued for 15 minutes under a vacuum of 4 mm. A total of 35 g. of distillate is collected, equivalent to 94% of the calculated amount.
The product is substantially the same as that made by reacting N-(2-chloroethoxymethyl)acrylamide with trimethylamine.
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The N-(chloroalkoxymethyl)acrylamides provide a practical means for the manufacture of vinyl quaternary compounds and water-soluble acrylamide polymers which contain vinyl quaternary linkages. Such polymers possess valuable dry strengthening properties when used in the manufacture of paper.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a method of making a rotary printing screen and, more particularly, to a method of forming by electro-metal deposition a rotary printing screen with each of the mesh areas having a mesh design in an area depressed from the external surface of the rotary printing screen.
2. Description of the Prior Art
U.S. Pat. No. 4,184,925 teaches the fabricating of an orifice plate for a jet drop recorder by a technique requiring alternate photoresist and nickel plating operations. The first resist and plating sequence results in an orifice recess on one side of the plate while the second sequence produces a large cavity on the side of the plate opposite the recess. The second plating step also thickens the orifice plate.
U.S. Pat. No. 4,080,267 relates to a thick self-supporting mask for electronic beam projection processes made by multiple steps of coating with resist, exposure, development, and plating. Second and third sequences of the same steps generate large apertures in the mask.
U.S. Pat. No. 3,759,800 discloses a method of making a rotary printing screen whereby an electro-deposited metal sleeve is etched to produce a pattern of holes. A fabric sleeve is mounted over the metal sleeve and further plating of the metal sleeve with the fabric sleeve in place locks the fabric on the metal sleeve. A printing image is then built up on the screen providing openings which are much larger than the openings in th fabric thereby permitting more air to pass through the metal base and giving finer detail in the printing operation.
U.S. Pat. No. 3,772,160 teaches electroforming a printing screen whereby a nickel pattern comprising the masking surface of the pattern to be reproduced is first electro-deposited, then an eutectic alloy is deposited onto the nickel surface and a wire screen is pressed into the alloy layer. The screen bridges the gaps in the nickel mask layer representing the symbol to be reproduced.
SUMMARY OF THE INVENTION
The method to be used to make a built up area screen is as follows. First, coat, expose and then develop a photoresist coating on a mandrel surface with the desired printing pattern which has the areas through which ink passes defined as a mesh area. The resist coated mandrel surface is plated in a conventional manner to the desired thickness. The plated screen is left on the mandrel and a second photoresist coating is applied over the entire mandrel surface. The photoresist coating is exposed to polymerize those areas where the mesh is located on the original plated screen and not exposed in those areas which are not preforated by a mesh pattern. The new resist coating is developed and the resulting product is then plated by a conventional means. The plating is carried out to provide a surface of desired thickness. When the plating is stopped and the screen is removed from the tank and cleaned up, it will be found that in those areas where there is no mesh pattern, the screen is at least of double thickness. In those areas where there is a mesh pattern, the screen is of a single thickness with an enlarged recess open area being disposed between the mesh pattern and the outside surface of the rotary screen printer.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of developed resist coating;
FIG. 2 is a perspective view of a plated pattern formed from the resist coating of FIG. 1;
FIG. 3 is a side view of FIG. 2;
FIG. 4 is the FIG. 3 structure covered with a resist coating prior to development;
FIG. 5 is the structure of FIG. 4 after the resist coating has been exposed and developed; and
FIG. 6 is a cross-sectional view of a portion of rotary printing screen.
DESCRIPTION OF THE PREFERRED EMBODIMENT
It is desired to produce a rotary printing screen which is capable of depositing increased quantities of ink or other coating materials over that normally deposited with a conventional rotary printing screen. The screen would be particularly useful for depositing ink on relatively thick substrates such as resilient flooring material or carpeting. Normally, a rotary screen is provided with a mesh area with a certain design through which ink is passed to deposit the ink in the design of the mesh area. The periphery of the mesh area defines the design and the mesh area is really a plurality of holes within the periphery of the mesh area. Normally, the perforations of the mesh area extend completely through the thickness of the rotary screen. This means that all of the ink being pushed through a single hole in the mesh must penetrate completely into the substrate. No deposition of an ink will be left on the surface of the substrate because the outside surface of the screen is against the substrate and any ink within the perforation will stay within the perforation as the screen rotates away from the substrate. In order to get a deposition of an ink on a substrate, the structure of FIG. 6 of the drawing is needed. Here the substrate 2 has the rotary screen 4 pressing thereagainst. The outside surface of the screen 6 is in contact with the upper surface of the substrate 2. Printing ink will be in the region 8 and will pass through the perforations 10 and 12 to be deposited on the substrate. Normally, the perforations would be in the form of the single perforation 14 shown in dotted line on the left of FIG. 6. Thus, it will be seen that any ink within the perforation 14 would stay within that perforation when the screen 4 and substrate 2 separate and no deposition of excess material would be left on the surface of the substrate. It should be noted that the perforations in the screen are in the order of about 8 mils in diameter and conventional printing ink would be, by surface tension, retained within the perforation upon the separation of the printing screen and substrate rather than dripped out of the perforation onto the surface of the substrate.
For simplicity herein the mesh area through which the ink penetrates is being shown as either two perforations or as four perforations. In reality, the real product is made with 300-1000 perforations per square inch and a region that has a plurality of perforations therein is called the mesh area of the screen, and this has a particular shape or design based upon the peripheral shape or design of the mesh. Ink passing through all the holes in the mesh will form a printing on a substrate of the shape of the periphery of the mesh area. In those areas where it is not desired that ink pass through the screen, the area is not perforated and no mesh pattern exists. By looking at FIG. 6, when ink passes through the perforations 10 and 12, there is a recessed chamber 16 therebelow which will receive excess ink and permit excess ink to sit on the surface of the substrate 2. In some printing operations, this would be desirable and it can be accomplished only by the structure of FIG. 6.
In order to accomplish the structure of FIG. 6, the below defined method must be utilized. The method utilizes the electro deposition of metal on a surface that has been provided with a pattern due to the use of photoresist materials. Photoresist materials form a raised pattern around which the metal is electrically deposited. Consequently, if one was trying to make a solid sheet, there would be no resist deposited upon the surface to be plated. In areas where one wished to form a mesh or perforated pattern, then a plurality of columns of resist would be formed in the arrangement and shape that one desired to have the perforations in the end product. Metal is then deposited around these columns of resist material and there is formed a metallic surface having a plurality of perforations therein, the perforations being in the shape and design of the columns of resist.
In order to form a rotary printing screen, the resist material must be deposited on some surface. Normally, this surface is in the form of a mandrel which is basically nothing more than a cylindrical sleeve which has on the outside thereof a surface which can have photoresist material adhered thereto. The first step of the process is to coat the outside surface of the mandrel with a photoresist material such as the Shipley Co. Photoresist AZ119 which is a positive photoresist. This resist is deposited to a thickness of about 1 mil. A film is placed thereover with the film containing a pattern similar to that which one desires to form in the resist. The film is exposed in a conventional manner using UV light collimated to get parallel rays of light. The exposure is carried out from 15 minutes to 3 hours, depending upon the specific resist material being utilized. The resist material is then developed and the mandrel washed resulting in the forming on the surface of the mandrel of a deposition of hardened resist material in a pattern, the pattern being determined by the image on the film. Up to this point, what has been performed is conventional in the art. In forming the rotary screen, there will be formed areas where no resist is present at all, and this will form non-perforated areas of the rotary screen. In other areas on the mandrel, there will be formed little columns of resist material. The columns will be grouped in areas to form a pattern and the periphery area of these groups of columns of resist will define the mesh periphery. The columns of resist will form the perforations which will be in the metal coating that will be deposited subsequently on the mandrel coated with the resist. For simplicity's sake, in FIG. 1, there is shown just a portion of a mandrel with four columns 18 of resist material formed on the surface of the mandrel 20. These columns of resist material stand up about 1 mil in height and would be approximately 8 mils in diameter.
The mandrel is now placed in a conventional plating tank to electro deposit metal, preferably nickel, upon the surface of the mandrel. About 3 to 4 mils of metal are deposited on the surface of the mandrel in a conventional manner. In FIG. 1, in the region 22 of the mandrel 20 where no resist exists, a solid surface of nickel will be formed. In the region of the columns of resist 18, the metal will be deposited around the columns 18 and the columns of resist will, in effect, have nickel formed therearound. When the resist is ultimately removed from the surface of the nickel, there would then be provided perforations through the nickel. The structure resulting from the nickel plating operation of FIG. 1 will then look like the structure of FIG. 2 wherein the columns 18 of resist are removed and the region 22 is covered with nickel along with all of the area adjacent and in between the holes 19 where the columns 18 had been. Assuming that the nickel coated surface was removed from the mandrel in FIG. 2 and one looked at that structure in cross-section, one would see a structure similar to that of FIG. 3 wherein the holes 19 are shown completely surrounded by a deposition of nickel material 24. Referring now to FIG. 4, the nickel plated surface 24 of mandrel 20 is still formed with the columns of resist 18 therein. Alternatively, the column 18 could have been washed therefrom when the product of the first plating operation was cleaned up and prepared for the next plating operation. The second resist coating 26 is then deposited over the previously plated surface 24. The resist material will bridge the holes 19 which exist in the layer 24 or will simply fill the holes 19 formed during the first plating operation. The second resist 26 could be Kodak KPR photoresist which would be sprayed on the surface 24 and this would completely cover the surface 24 to a depth of about 3 mils and would fill in the areas 18 should they not still contain resist material. By the use of DuPont "Riston" resist sheet material which would simply be laid or laminated across layer 24, a resist coating 26 would be formed, and this would simply bridge the holes 19 rather than filling them. Now one will place another film over top of the resist and the purpose of this film is to form the recessed areas in the region of the mesh pattern formed by the holes in the first coating 24. Exposure and development of the second resist coating is carried out in a conventional manner and a structure similar to FIG. 5 is formed wherein the second layer of resist is now left as a hardened resist coating in the region 28, and the region 28 is within the perimeter of the mesh area defined by the plurality of perforations in the layer 24. The original coating 24 of nickel is activated or washed with a 50% hydrochloric acid solution or other nickel activation techniques in order to prepare it for a subsequent plating operation. The mandrel with the first plating layer 24 thereon and the second resist coating 28 thereon is then inserted into a conventional plating tank, and the plating is carried out at a slightly lower than normal plating condition wherein the plating is carried out at a lower current density of 10 to 20 amp/ft 2 . This then deposits on the surface of layer 24 in the region where there is no resist another nickel coating of 10 mils which combines with the nickel coating 24 to form the thick nickel layer defined and shown in FIG. 6 as thickness 30. However, due to the presence of the resist 28 in the area of the mesh pattern, a recessed area 16 is formed. After the second nickel plating operation is carried out, the resist area 28 is washed out of the area 16 and the perforations 10 and 12 are cleaned out and the plated metal sleeve is removed from the mandrel. Now one has perforations 10 and 12 leading into enlarged area 16 and there is thus provided a mesh area defined by apertures 10 and 12 spaced from the surface of substrate 2 due to the presence of the area 16. Consequently, there is now provided a structure which will permit the deposition of printing ink or other coating material upon the surface of the substrate being printed.
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A rotary printing screen is made with selected areas being provided with a perforated mesh region through which printing ink may be passed. These mesh areas are provided with a mesh pattern recessed back from the exterior surface of the rotary printing screen so as to permit greater ink deposition thicknesses. The screen is formed by an electro-metal deposition method which provides a basic conventional screen structure. The mesh areas are then masked and an additional deposition of material is provided in the non-mesh areas to build up these areas and, consequently, provide a recessed area in the region of the originally formed mesh design.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a semiconductor stack and more particularly relates to a semiconductor stack composed of a positive switching device and a negative switching device in which two terminals of the positive side and the negative side thereof are led to the same surface.
2. Description of the Related Art
Currently, the high-frequency pulse width modulation (PWM) control method which uses high-speed switching devices is being widely used in power converters. As the capacity of the power converter is made larger, large capacity high-speed switching devices are being used in parallel. Also, in the high-frequency PWM control method, in order to suppress surge voltage generated during switching by reducing the reactance between high-speed switching devices, the high-speed switching devices are installed close to each other and their distance from the capacitor is shorter.
A prior art semiconductor stack is described below with reference to FIGS. 10, 11(a), and 11(b).
FIG. 10 shows a circuit construction of a semiconductor stack 7 composed of the two arms of the positive side and negative side of a given AC phase in a three-phase or single phase bridge circuit. In this circuit, 6 parallel semiconductor switching devices 1a, 1b, 1c, 1d, 1e, 1f and 6 parallel semiconductor switching devices 2a, 2b, 2c, 2d, 2e, 2f, each composed of a transistor, are connected in series between DC terminals 9 and 10. Also in this circuit, two capacitors 15 are connected between DC terminals 9 and 10. Devices 1a-1c are connected in parallel between a DC conductor 3H and an AC conductor 5H. Devices 1d-1f are connected in parallel between a DC conductor 3R and an AC conductor 5R. Devices 2a-2c are connected in parallel between AC conductor 5H, and a DC conductor 4H. Devices 2d-2f are connected in parallel between AC conductor 5R and a DC conductor 4R. An AC terminal 11 is led from AC conductors 5H, 5R. The connection between capacitors 15 and DC terminals 9 and 10 is carried out by DC conductors 3a and 4a, respectively.
FIGS. 11(a) and 11(b) show the packaging of prior art semiconductor stack 7 shown in FIG. 10. FIG. 11(a) is a plan and FIG. 11(b) is a right side elevation.
In FIG. 11(a) and 11(b), devices 1a-1f and 2a-2f are arranged, six to each face, on the two faces of a heat receiving unit 6a of a heat sink 6 with a built-in heat pipe. Devices 1a and 2a, devices 1b and 2b, and devices 1c and 2c are arranged in sequence on the front surface of heat receiving unit 6a of heat sink 6 from a heat radiation unit 6b side. Positive terminals C of devices 1a, 1b and 1c are each connected to DC conductor 3H which is extended from near heat radiation unit 6b of heat sink 6. DG conductor 3H is connected to DC conductor 3a through DC terminal 9. Negative terminals E of devices 1a, 1b and 1c and positive terminals C of devices 2a, 2b and 2c are each connected to AC conductor 5H which is extended from near heat radiation unit 6b. The end of AC conductor 5H forms AC terminal 11. Negative terminals E of devices 2a, 2b and 2c are each connected to DC conductor 4H which is extended from near heat radiation unit 6b. DC conductor 4H is connected to DC conductor 4a through DC terminal 10. The other ends of DC conductor 3a and DC conductor 4a are respectively connected to the positive terminals and the negative terminals of capacitors 15.
Also, devices 1d and 2d, devices 1e and 2e, and devices 1f and 2f are arranged in sequence from heat radiation unit 6b side on the rear surface of heat receiver 6a of heat sink 6 in the same way as for the front surface. Positive terminals C and negative terminals E of these devices are connected to one of two DC conductors 3R and 4R and AC conductor 5R in the same way as for the front surface. As shown in FIG. 11(a), AC terminal 11 is arranged in a position close to and equidistant from DC terminals 9 and 10. Also, each of conductors 3H, 3R, 4H, 4R, 5H and 5R is formed in a belt shape, as shown in FIG. 11(a) and 11(b).
In FIG. 11(b), only DC conductors 4H and 4R and DC conductor 4a are shown. A DC conductor is composed by DC conductors 3H and 3R; a DC conductor is composed by DC conductors 4H and 4R; and an AC conductor is composed by AC conductors 5H and 5R.
As shown in FIG. 11(b), each of the DC conductors 3H, 4H, 3R and 4R and AC conductors 5H and 5R positioned on the front and rear faces of heat receiving unit 6a is respectively bent toward the end surface of heat receiving unit 6a at the front of heat receiving unit 6a. DC terminals 9 and 10 and AC terminal 11 are arranged at intermediate positions of DC conductors 3H and 3R, DC conductors 4H and 4R, and AC conductors 5H and 5R, respectively.
However, in this type of composition in which AC conductors and DC conductors are arranged three-dimensionally by making them belt-shaped and dividing them, there is a limit to making the wiring reactance of the circuit smaller and to suppressing surge voltages during the switching action of each device.
There is also an imbalance between currents flowing through each of devices connected in parallel caused by the difference between the distances from each of the devices to DC or AC terminal.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a semiconductor stack which can make the circuit reactance smaller and can further suppress voltages during the switching action of each device.
Another object of this invention is to provide a semiconductor stack which can improve the balance of currents flowing through each of devices connected in parallel.
These and other objects of this invention can be achieved by providing a semiconductor stack including a base member and a semiconductor assembly member provided on the base member. The semiconductor assembly member includes a switching element having a first, a second and a third terminal, mounted on a surface of the base member such that the first, second and third terminals of the switching element are led to a same plane, and a batch laminated conductor positioned on the first, second and third terminals of the switching element, composed of superimposition of a first, a second and a third conductor and insulators for insulating between adjacent two of the conductors. The semiconductor assembly member also includes a first, a second and a third connecting device for connecting the first, second and third conductors and the first, second and third terminals of the switching element, respectively. The first, second and third connecting devices thrust through the batch laminated conductor in a state in which the first, second and third connecting devices are electrically connected to the first, second and third conductors and are insulated from the second and third conductors, the first and third conductors and the first and second conductors, respectively.
According to one aspect of this invention, there is provided a semiconductor stack including a base member, a first semiconductor assembly member provided on a first surface of the base member and a second semiconductor assembly member provided on a second surface of the base member. Each of the first and second semiconductor assembly members includes a switching element having a first, a second and a third terminal, mounted on one of the first and second surfaces of the base member such that the first, second and third terminals of the switching element are led to a same plane, and a batch laminated conductor positioned on the first, second and third terminals of the switching element, composed of superimposition of a first, a second and a third conductor and insulators for insulating between adjacent two of the conductors. The batch laminated conductor includes a first, a second and a third connection portion electrically connected to the first, second and third conductors, respectively. Each of the first and second semiconductor assembly members also includes a first, a second and a third connecting device for connecting the first, second and third conductors and the first, second and third terminals of the switching element, respectively. The first, second and third connecting devices thrust through the batch laminated conductor in a state in which the first, second and third connecting devices are electrically connected to the first, second and third conductors and are insulated from the second and third conductors, the first and third conductors and the first and second conductors, respectively. Each of the first and second semiconductor assembly members further includes a first, a second and a third conductor connecting device for connecting the first, second and third connection portions of the first and second semiconductor assembly members, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIGS. 1(a) and 1(b) are respectively front and side elevations showing a semiconductor stack according to an embodiment of this invention;
FIG. 2 is an exploded oblique view showing part of the batch laminated conductor on the front surface of the embodiment shown in FIGS. 1(a) and 1(b);
FIG. 3 is an exploded oblique view showing another part of the batch laminated conductor on the front surface of the embodiment shown in FIGS. 1(a) and 1(b);
FIG. 4 is an exploded oblique view showing part of the batch laminated conductor on the rear surface of the embodiment shown in FIGS. 1(a) and 1(b);
FIG. 5 is an exploded oblique view showing another part of the batch laminated conductor on the rear surface of the embodiment shown in FIGS. 1(a) and 1(b);
FIGS. 6(a) and 6(b) are respectively front and side elevations showing a front surface batch laminated conductor;
FIGS. 7(a)-7(f) are cross-sectional views taken respectively on lines VIIA-VIIA to VIIF-VIIF in FIG. 6(a) and showing the batch laminated conductor shown in FIG. 6(a);
FIGS. 8(a) and 8(b) are respectively rear and side elevations showing a rear surface batch laminated conductor;
FIGS. 9(a)-9(f) are cross-sectional views taken respectively on lines IXA-IXA to IXF-IXF in FIG. 8(a) showing the batch laminated conductor FIG. 8(a);
FIG. 10 is a circuit diagram of the switching devices and capacitor incorporated in a semiconductor stack; and
FIGS. 11(a) and 11(b) are respective front and side elevational views showing a prior art semiconductor stack.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, the embodiments of this invention will be described below.
The following is a description of an embodiment of this invention with reference to FIGS. 1-9. FIG. 1(a) is a plan showing the packaged state of the front surface of a semiconductor stack 7A according to an embodiment of this invention, and FIG. 1(b) is its right side elevation. The packaged circuit is identical to that shown in FIG. 10 except connecting conductors.
As shown in FIGS. 1(a) and 1(b), devices 1a-1c and 2a-2c are arranged on heat receiving unit 6a of heat sink 6 on the front side of semiconductor stack 7A in the same way as in FIGS. 11(a) and 11(b). A batch laminated conductor 8 is arranged on terminals C and E of devices 1a-1c and 2a-2c so that it covers each terminal. Similarly devices 1d-1f and 2d-2f are arranged on heat receiving unit 6a of heat sink 6 on the rear side of semiconductor stack 7A. A batch laminated conductor 16 is arranged on terminals C and E of devices 1d-1f and 2d-2f so that it covers each terminal. Each conductor of batch laminated conductor 16 is bent toward the front surface of heat receiving unit 6a at the front of heat receiving unit 6a, and it joined to each corresponding conductor of batch laminated conductor 8 on the front surface, as described later in detail.
FIGS. 2 and 3 are parts of an exploded oblique view of batch laminated conductor 8, respectively, and the two parts together form batch laminated conductor 8. Batch laminated conductor 8 shown in FIGS. 2 and 3 is positioned on the front side of heat receiving unit 6a as described above, and is composed by the superimposition of a DC conductor 3b, a DC conductor 4b, an AC conductor 5b between them, and four insulating plates 20b, 21b, 22b and 23b which sandwich each of these conductors 3b, 4b and 5b. These are laminated in the sequence from the side which is in contact with each of terminals C and E of devices 1a-1c and 2a-2c of: insulating plate 23b, DC conductor 4b, insulating plate 22b, AC conductor 5b, insulating plate 21b, DC conductor 3b, insulating plate 20b.
FIGS. 4 and 5 are parts of an exploded oblique view of batch laminated conductor 16, respectively, and the two parts together compose batch laminated conductor 16.
Batch laminated conductor 16 shown in FIGS. 4 and 5 is positioned on the rear side of heat receiving unit 6a, and is composed by the superimposition of a DC conductor 3c, a DC conductor 4c, an AC conductor 5c between them, and four insulating plates 20c, 21c, 22c and 23c which sandwich each of these conductors 3c, 4c and 5c. These are laminated in the sequence from the side which is in contact with each of terminals C and E of devices 1d-1f and 2d-2f of: insulating plate 23c, DC conductor 4c, insulating plate 22c, AC conductor 5c, insulating plate 21c, DC conductor 3c, insulating plate 20c.
In batch-laminated conductors 8 and 16, each of DC conductors 3b, 4b, 3c and 4c and AC conductors 5b and 5c is made of a copper plate (tin-plated, 2 mm thick), and each of insulating plates 20b, 21b, 22b, 23b, 20c, 21c, 22c and 23c is made of a PPS (polyphenylene sulfide) plate of 2 mm thickness.
As shown in FIGS. 2-5, L-shaped capacitor connecters 3bc, 3cb, 4bc and 4cb which connect with capacitors 15 are respectively attached to the leading edges of DC conductors 3b, 3c, 4b and 4c. Capacitor connectors 3cb and 4cb, which are positioned on the rear side, are bent toward the front surface of heat receiving unit 6a at the front of heat receiving unit 6a so that they can be connected to capacitor connectors 3bc and 4bc and to the positive and negative terminals of capacitors 15 on the front side of heat receiving unit 6. Also, a connector formed in a U-shape which is bent toward the front surface of heat receiving unit 6a at the front side of heat receiving unit 6a is provided on the leading edge of AC conductor 5c which is positioned on the rear side, so that it can be connected with AC conductor 5b. A gap is formed between each of DC conductors 3b, 3c, 4b and 4c and each of their capacitor connectors 3bc, 3cb, 4bc and 4cb by making each of capacitor connectors 3bc, 3cb, 4bc and 4cb L-shaped. Therefore, the connector of AC conductor 5c can be extended from the rear to the front. As a result, connection of AC conductor 5b and AC conductor 5c is made possible, through the U-shaped connector of AC conductor 5.
FIG. 6(a) is a plan of batch laminated conductor 8 seen from the front, that is from left side in FIG. 1(b). FIG. 6(b) is a right side elevation of this. FIGS. 7(a)-7(f) are cross-sectional views taken respectively on lines VIIA-VIIA to VIIF-VIIF in FIG. 6(a).
FIG. 8(a) is a plan of batch laminated conductor 16 seen from the front, that is from right side in FIG. 1(b). FIG. 8(b) is a side elevation of this. FIGS. 9(a)-9(f) are cross-sectional views taken respectively on lines IXA-IXA to IXF-IXF in FIG. 8(a).
The following is a description of batch laminated conductor 8. As shown in FIGS. 2 and 3, holes are opened in the insulating plates as follows: I 1 -I 12 in insulating plate 20b; I 13 -I 24 in insulating plate 21b; I 25 -I 36 in insulating plate 22b and I 37 -I 48 in insulating plate 23b. These holes I 1 -I 48 are provided for thrusting through conductor collars (described later) which connect DC conductors 3b and 4b and AC conductor 5b with terminals C and E of devices 1a-1c and 2a-2c. Also further holes are opened in the insulating plates as follows: I A -I D in insulating plate 20b; I E -I H in insulating plate 21b; I I -I L in insulating plate 22b and I M -I P in insulating plate 23b. These holes I A -I P are provided for insulated securing bolts 14 which secure the whole of batch laminated conductor 8 (See FIG. 6(a) and FIG. 7(b)).
In FIG. 2, conductor collars PB 1 -PB 6 are mounted on DC conductors 3b. Conductor collars PB 1 and PB 4 , PB 2 and PB 5 , PB 3 and PB 6 are respectively incorporated as one. Hollow space is provided in each of the centers of these for passing through a terminal connecting bolt 13. The conductor collars (described later) also have hollow spaces for passing through terminal connecting bolts 13. As shown in FIG. 7(c), positive terminal C of device 1c is electrically connected to DC conductor 3b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars PB 1 and PB 4 . Similarly, positive terminal C of device 1b is electrically connected to DC conductor 3b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars PB 2 and PB 5 . Positive terminal C of device 1a is electrically connected to DC conductor 3b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars PB 3 and PB.sub. 6. Also, holes P 5 -P 7 , holes P 25 -P 27 and holes P 28 -P 30 are opened in DC conductor 3b. These holes are respectively provided for thrusting through conductor collars ACB 1 -ACB 3 , conductor collars ACB 7 -ACB 9 and conductor collars NB 1 -NB 3 (described later). These holes are provided in sizes such that each of these conductor collars and DC conductor 3b do not make contact with each other so that these conductor collars are insulated from DC conductor 3b. Moreover, holes P 1 -P 4 for insulated securing bolts 14 are opened in DC conductor 3b. Holes P 8 and P 9 are opened in capacitor connector 3bc of DC conductor 3b for conductor collars PB 13 and PB 14 (described later) which connect DC conductor 3b and DC conductor 3c and the positive terminals of capacitors 15.
In FIG. 3, conductor collars NB 1 -NB 6 are mounted on DC conductor 4b. Conductor collars NB 1 and NB 4 , NB 2 and NB 5 , NB 3 and NB 6 are respectively incorporated as one. As shown in FIG. 7(f), negative terminal E of device 2c is electrically connected to DC conductor 4b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars NB 1 and NB 4 . Similarly, negative terminal E of device 2b is electrically connected to DC conductor 4b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars NB 2 and NB 5 . Negative terminal E of device 2a is electrically connected to DC conductor 4b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars NB 3 and NB 6 . Also, holes N 5 -N 7 , holes N 25 -N 27 and holes N 28 -N 30 are opened in DC conductor 4b. These holes are respectively provided for thrusting through conductor collars ACB 10 -ACB 12 , conductor collars ACB 4 -ACB 6 and conductor collars PB 4 -PB 6 (described above). These holes are provided in sizes such that each of these conductor collars and DC conductor 4b do not make contact with each other so that these conductor collars are insulated from DC conductor 4b. Moreover, holes N 1 -N 4 for insulated securing bolts 14 are opened in DC conductor 4b. Holes N 8 and N 9 are opened in capacitor connector 4bc of DC conductor 4b for conductor collars NB 13 and NB 14 (described later) which connect DC conductor 4b and DC conductor 4c and the negative terminals of capacitors 15.
In FIG. 2, conductor collars ACB 1 -ACB 6 and ACB 1 -ACB 12 are mounted on AC conductor 5b. Conductor collars ACB 1 and ACB 4 , ACB 2 and ACB 5 , ACB 3 and ACB 6 , ACB 7 ; and ACB 10 , ACB 8 and ACB 11 , ACB 9 and ACB 12 are respectively incorporated as one. As shown in FIG. 7(d) and (e), negative terminal E of device 1c is electrically connected to AC conductor 5b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars ACB 1 and ACB 4 . Similarly, negative terminal E of device 1b is electrically connected to AC conductor 5b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars ACB 2 and ACB 5 . Negative terminal E of device 1a is electrically connected to AC conductor 5b by terminal connecting bolt 13 (not shown) which is thrust through conductor collars ACB 3 and ACB 6 . Similarly, positive terminal C of device 2c, positive terminal C of device 2b and positive terminal C of device 2a are connected to AC conductor 5b by terminal connecting bolts 13 (not shown) which are respectively thrust through conductor collars ACB 7 and ACB 10 , conductor collars ACB 8 and ACBA 11 , and conductor collars ACB 9 and ACB 12 . Also, holes AC 19 -AC 21 and holes AC 22 -AC 24 are opened in AC conductor 5b. Also, holes are respectively provided for thrusting through conductor collars NB 1 -NB 3 , and conductor collars PB 4 -PB 6 . These holes are provided in sizes such that each of these conductor collars and DC conductor 5b do not make contact with each other so that these conductor collars are insulated from AC conductor 5b. Moreover, holes AC 1 -AC 4 for insulated securing bolts 14 are opened in AC conductor 5b, and holes AC 5 and AC 6 for connecting bolts 17 (see FIG. 1(b)), which electrically connect AC conductor 5b to AC conductor 5c, are opened in AC conductor 5b.
The following is a description of batch laminated conductor 16. As shown in FIGS. 4 and 5, holes are opened in the insulating plates as follows: I 49 -I 60 in insulating plate 20c; I 61 -I 72 in insulating plate 21c; I 73 -I 84 in insulating plate 22c and I 85 -I 96 in insulating plate 23c. These holes I 49 -I 96 are provided for thrusting through conductor collars (described later) which connect DC conductors 3c and 4c and AC conductor 5c with terminals C and E of devices 1d-1f and 2d-2f. Also, further holes are opened in the insulating plates as follows: I Q -I T in insulating plate 20c; I U -I X in insulating plate 21c; I y -I Z , I AA and I AB in insulating plate 22c and I AC , I AD , I AE and I AF in insulating plate 23c. These holes I Q -I AF are provided for insulated securing bolts 14 which secure the whole of batch laminated conductor 16 (See FIG. 8(a) and FIG. 9(b)).
In FIG. 4, conductor collars PB 7 -PB 12 are mounted on DC conductor 3c. Conductor collars PB 7 and PB 10 , PB 8 and PB 11 , PB 9 and PB 12 are respectively incorporated as one. As shown in FIG. 9(c), positive terminal C of device 1f is electrically connected to DC conductor 3c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars PB 7 and PB 10 . Similarly, positive terminal C of device 1e is electrically connected to DC conductor 3c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars PB 8 and PB 11 . Positive terminal C of device 1d is electrically connected to DC conductor 3c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars PB 9 and PB 12 . Also, holes P 14 -P 16 , holes P 19 -P 21 and holes P 22 -P 24 are opened in DC conductor 3c. These holes are respectively provided for thrusting through conductor collars ACB 13 -ACB 15 , conductor collars ACB 19 -ACB 21 and conductor collars NB 7 -NB 9 (described later). These holes are provided in sizes such that each of these conductor collars and DC conductor 3c do not make contact with each other so that these conductor collars are insulated from DC conductor 3c. Moreover, holes P 10 -P 13 for insulated securing bolts 14 are opened in DC conductor 3c. Holes P 17 and P 18 are opened in capacitor connector 3cb of DC conductor 3c for conductor collars PB 13 and P 14 , which connect DC conductor 3b and DC conductor 3c and the positive terminals of capacitors 15.
In FIG. 5, conductor collars NB 7 -NB 12 are mounted on DC conductor 4c. Conductor collars NB 7 and NB 10 , NB 8 and NB 11 , NB 9 and NB 12 are respectively incorporated as one. As shown in FIG. 9(f), negative terminal E of device 2f is electrically connected to DC conductor 4c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars NB 7 and NB 10 . Similarly, negative terminal E of device 2e is electrically connected to DC conductor 4c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars NB 8 and NB 11 . Negative terminal E of device 2d is electrically connected to DC conductor 4c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars NB 9 and NB 12 . Also, holes N 14 -N 16 , holes N 19 -N 21 and holes N 22 -N 24 are opened in DC conductor 4c. These holes are respectively provided for thrusting through conductor collars ACB 19 -ACB 21 , conductor collars ACB 13 -ACB 15 (described later) and conductor collars PB 10 -PB 12 (described above). These holes are provided in sizes such that each of these conductor collars and DC conductor 4c do not make contact with each other so that these conductor collars are insulated from DC conductor 4c. Moreover, holes N 10 -N 13 for insulated securing bolts 14 are opened in DC conductor 4b. Holes N 17 and N 18 are opened in capacitor connector 4cb of DC conductor 4c for conductor collars NB 13 and NB 14 , which connect DC conductor 4b and DC conductor 4c and the negative terminals of capacitors 15. In FIG. 4, conductor collars ACB 19 -ACB 24 and ACB 13 -ACB 18 are mounted on AC conductor 5c. Conductor collars ACB 19 and ACB 22 , ACB 20 and ACB 23 , ACB 21 and ACB 24 , ACB 13 and ACB 16 , ACB 14 and ACB 17 , ACB 15 and ACB 18 are respectively incorporated as one. As shown in FIG. 9(d) and (e), negative terminal E of device 1f is electrically connected to AC conductor 5c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars ACB 13 and ACB 16 . Similarly, negative terminal E of device 1e is electrically connected to AC conductor 5c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars ACB 14 and ACB 11 . Negative terminal E of device 1d is electrically connected to AC conductor 5c by terminal connecting bolt 13 (not shown) which is thrust through conductor collars ACB 15 and ACB 18 . Similarly, positive terminal C of device 2f, positive terminal C of device 2e and positive terminal C of device 2d are connected to AC conductor 5c by terminal connecting bolts 13 (not shown) which are respectively thrust through conductor collars ACB 19 and ACB 22 , conductor collars ACB 20 and ACB 23 , and conductor collars ACB 21 and ACB 24 . Also, holes AC 11 -AC 13 and holes AC 14 -AC 16 are opened in AC conductor 5c. These holes are respectively provided for thrusting through conductor collars NB 7 -NB 9 , and conductor collars PB 10 -PB 12 (described above). These holes are provided in sizes such that each of these conductor collars and DC conductor 5c do not make contact with each other so that these conductor collars are insulated from AC conductor 5c. Moreover, holes AC 1 -AC 4 for insulated securing bolts 14 are opened in AC conductor 5c, and holes AC 17 and AC 18 for connecting bolts 17, which electrically connect AC conductor 5c to AC conductor 5b, are opened in AC conductor 5c.
In this way, DC conductors and an AC conductor and insulators are incorporated as a batch laminated conductor which are arranged on the switching devices. By this means, the connecting distance between conductors can be shortened without dividing the connections between the terminals of the devices and the capacitor into two. Therefore, the wiring reactance can be made smaller, about one half of that in stack 7 shown in FIGS. 11(a) and 11(b), and surge voltages during switching operations can be suppressed. The balance of currents flowing through each of devices connected in parallel is improved, because the DC and AC conductors are plate-shaped so the actual resistances between each of the devices and the DC or AC terminal become approximately equal. Furthermore, since the conductors are incorporated as a batch laminated conductor, labour time for connecting the conductors can be shortened.
In the embodiment, a batch laminated conductor is composed by the superimposition of DC conductors 3b and 3c, DC conductors 4b and 4c, AC conductors 5b and 5c and multiple insulators. However, a laminated composition in which each conductor surface is coated with an insulating agent without using separate insulating sheets may also be used. Moreover, in the embodiment, switching devices which have a positive terminal and a negative terminal each are used in pairs on the front surface and the rear surface. Therefore a composition in which a total of four terminals are led to the outside has been described. However, a batch laminated conductor having a similar composition to that of the embodiment can be used for two-in one type switching devices each having a common connecting terminal apart from a positive terminal and a negative terminal, that is a total of three terminals, are led out.
When using this invention, a semiconductor stack can be achieved which is capable of making the circuit wiring reactance smaller and further suppressing surge voltages during the switching operation of each device. Furthermore, a semiconductor stack can be achieved which can improve the balance of currents flowing through the devices.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A semiconductor stack including a base member and a semiconductor assembly member provided on the base member. The semiconductor assembly member includes a switching element having a first, a second and a third terminal, mounted on a surface of the base member such that the first, second and third terminals of the switching element are led to a same plane, and a batch laminated conductor positioned on the first, second and third terminals of the switching element, composed of superimposition of a first, a second and a third conductor and insulators for insulating between adjacent two of the conductors. The semiconductor assembly member also includes a first, a second and a third connecting device for connecting the first, second and third conductors and the first, second and third terminals of the switching element, respectively. The first, second and third connecting devices thrust through the batch laminated conductor in a state in which the first, second and third connecting devices are electrically connected to the first, second and third conductors and are insulated from the second and third conductors, the first and third conductors and the first and second conductors, respectively.
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This application is a continuation-in-part of applicant's copending application Ser. No. 877,314, filed June 23, 1986, entitled "Metal Cutting Apparatus And Method", abandoned, which is a continuation of application Ser. No. 561,959 filed Dec. 16, 1983, entitled "Metal Cutting Apparatus And Method", abandoned, which is a continuation of application Ser. No. 273,479, filed June 15, 1981, entitled "Metal Cutting Apparatus And Method", abandoned. Accordingly, the present invention relates to the cold finishing of elongate metal stock such as rod, wire or the like and, more particularly, to an apparatus and method for effecting the removal of surface metal from continuously advanced metal stock.
BACKGROUND
In many instances it is desirable to remove unwanted surface metal from wire, rod and like elongate metal stock prior to further processing. This might be done, for example, to convert "scrap" stock into a high quality material suitable for use in many applications. Other reasons are to shape the stock for subsequent machining or use in straight cut lengths, or to provide dimensionally accurate rod or wire for cold heading, closed die forming, machining and spring making operations.
Heretofore various techniques have been employed to effect removal of surface material from wire and rods. Some of these techniques have involved the use of shaving tools or dies which cut or peel unwanted surface material from the metal stock as it is advanced by or through the shaving tool or die. For example, round dies have been used in cold or hot finishing operations to effect a reduction in the cross-sectional area of the metal stock being drawn therethrough. The use of such dies, however, has several disadvantages including their relatively high cost and the inability to be reshaped without increasing the die diameter.
Other shaving techniques involve the removal of metal in a series of stages spaced axially along the path of the stock and at differing angles about the stock, each stage accomplishing removal of surface metal from a corresponding side of the metal stock. Two proposed techniques of this nature are described in U.S. Pat. Nos. 2,638,818 and 2,703,512. In the former, the cutting elements at each stage are mounted on extension arms and posts which yieldingly urge the cutting elements together with or without assistance of springs. In the latter, each cutting element is mounted in a tool holder along with a back-up roll which loads the material stock against the cutting element.
Notwithstanding the many shaving or cutting techniques proposed in the past, none have been found to be entirely adequate. One difficulty has been chattering, such being evidenced by surface roughness of the metal stock and rapid wear of the cutting tool. Another drawback has been the inability to achieve high operational speeds such as on the order of 500 ft. per minute or higher with acceptable results. Still other drawbacks have been the inability to provide for selective removal of only defective surface material and a general lack of flexibility with respect to the shape or profile imparted to the metal stock.
SUMMARY OF THE INVENTION
According to the invention, an apparatus and method for shaving elongate metal stock such as rod, wire and the like is characterized by a plurality of progressive die stations each including diametrically opposed segmental dies which are automatically indexed to remove surface imperfections from metal stock, to impart desired cross-sectional shapes to the metal stock and/or to impart desired taper profiles to the metal stock. The segmental dies at each station are rigidly secured to respective carriages by heel and toe clamps and the carriages are radially advanced and retracted in rigid restraints by hydraulic actuators provided with adjustable mechanical stops which operate to limit inward carriage advancement. The carriages and hydraulic actuators for each station are mounted on a mounting plate which is securable to an upright support plate in any one of a number of rotated positions. The support plates are fixed at their lower ends to a base structure and tied together at their upper ends to adjacent support plates to eliminate or minimize chatter as the metal stock is continuously advanced through the progressive die stations.
To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail a certain illustrative embodiment of the invention, this being indicative, however, of but one of the various ways in which the principles of the invention may be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
In the annexed drawings:
FIG. 1 is a schematic plan view of a shaving apparatus according to the invention;
FIG. 2 is a perspective view of a major intermediate assembly of the overall apparatus employing three progressive die stations;
FIG. 3 is a transverse plan view of an illustrative one of the progressive die stations;
FIG. 4 is a vertical section through the die station of FIG. 3 taken substantially along the line 4--4 thereof;
FIG. 5 is a transverse plan view showing preferred segmental shaving dies and mounts therefor;
FIG. 6 is an axial plan view of the shaving dies and mounts of FIG. 5 as seen from the line 6--6 thereof; and
FIG. 7 is a schematic plan view of another embodiment of a shaving apparatus according to the invention.
DETAILED DESCRIPTION
Applicant's above identified copending application Ser. No. 877,314 is hereby fully incorporated herein by reference. The present invention embodies improvements to the apparatus and method disclosed in such copending application.
Referring now in detail to the drawings, the schematic diagram of FIG. 1 generally illustrates the apparatus and method of the invention for imparting a desired surface finish, cross-section and/or profile to metal stock such as rod, wire and the like. As shown, the metal stock 10 taken from a spool or other supply 11 is first passed through a straightener 12 and then through a guide die 13 into a lubricant or "soap" box 14. The lubricant box 14 serves to coat the metal stock with lubricant before passage through a preshaping die 15 at the exit opening of the box. If desired, the metal stock may be passed through an optional sand blasting chamber indicated at 16 for removal of loose scale, rust, etc. from the metal stock before passage through the lubricant box 14 and preshaping die 15.
The preshaping die 15 forms the metal stock 10 to a desired cross-section before passage through a plurality of progressive die stations 18-20 which are operated to shave surface metal from the metal stock. Depending on the application, such die stations may serve to effect removal of surface imperfections from the metal stock, to impart a desired cross-section to the metal stock and/or to impart a desired profile to the metal stock. As shown, three die stations may be provided, such constituting a desired number for most applications. However, four or more stations may be employed depending on the particular application, there being an optional fourth station shown in broken lines at 21. In one particular application discussed below, an optional flaw detector shown in phantom lines at 22 may be provided between the preshaping die 15 and the first die station 18.
After passage through the die stations 18-20, the metal stock then passes through a guide 24 and then through a forming die 25 in some applications before passage to a take-up device 26 or further processing line for the metal stock. The die 25 may be utilized for example to give the metal stock its final shape at the exit end of the apparatus. The take-up device 26 may be in the form of a rotatably driven "pull-block", although any suitable means may be employed to pull the metal stock through the apparatus at a desired processing speed.
As seen in FIG. 2, the major intermediate components of the apparatus are provided in an assembly indicated generally by reference numeral 30. The assembly 30 comprises a box-like base or stand 31 and a superstructure 32. The base 31 has a large rectangular platform plate 33 horizontally supported adjacent each side edge atop a vertical trapezoidal side plate 34. Also, the platform plate 33 is supported adjacent its end edges atop inclined rectangular end plates 35 which are secured between and to the inclined edges of the side plates 34.
The base 31 may be supported by grooved wheels 38 on parallel tracks 39 for transverse movement. This is desirable for shuttling of the apparatus into and out of alignment with one or more processing lines as may be desired. As shown, the rollers 38 are rotatably mounted to the ends of selected transversely extending tie plates 40 secured between and to the side plates 34 at their lower edges. The tie plates 40 are spaced along the length of the base and may support thereon respective vertical bracing plates 41 which in turn support the platform plate 33 at locations intermediate its ends to provide a rigid support for components mounted thereon.
The superstructure 32 includes two transversely extending upright plates 44 and 45 fixedly secured at their lower edges to and adjacent opposite ends of the platform plate 33. At their upper edges, the upright plates 44 and 45 have secured thereto respective ends of a horizontal cover plate 46. The cover plate 46 may be provided with a central opening therein and have mounted thereon a light fixture 47 for illuminating the interior space of the superstructure which contains the progressive die stations 18-20 which are more fully described below. The superstructure 32 also provides a convenient mount for the lubricating box 14 at the upright plate 44 and the guide 24 at the upright plate 45. The lubricating box 14 also may be supported at its bottom side by a gusset 48 which in turn is supported atop the platform plate 33 forwardly of the upright plate 44.
Each progressive die station 18-20 includes a respective segmental die mechanism 50-52. The segmental die mechanisms are essentially identical and differ only in their mounted orientation relative to the path of the metal stock therethrough, such path being illustrated by the arrows 53. Accordingly, only the segmental die mechanism 50 associated with the upstream station 18 will be described in further detail, it being appreciated that such description is equally applicable to the segmental die mechanisms 51 and 52 of the other stations 19 and 20.
With additional reference to FIGS. 3 and 4, the segmental die mechanism 50 is mounted by means of a mounting plate 54 to an upright support plate or stanchion 55 having a footer 56 secured atop the platform plate 33 by fasteners 57. At its downstream side opposite the mounting plate 54, the upright support plate 55 is rigidly backed by a pair of transversely spaced, vertical gussets 58 which serve to prevent oscillation of the support plate 55 at right angles to its planar extent. As best seen in FIG. 3, the support plate 55 has a circular top edge coinciding in radius with the mounting plate 54 which has the shape of a truncated circle. The mounting plate, with its bottom edge extending horizontally, is secured to the support plate 55 by two sets of fasteners 59 and 60, each set of fasteners being located along respective chords of the mounting plate in symmetrical relation to the fasteners located along the chord of the other set. The mounting plate further may be secured to the support plate by another fastener 61 located on the center radius of the mounting plate. As also seen in FIGS. 3 and 4, the support plate 55 is precisely located on the platform plate by locating pins 62. It also is noted that the support plate may be provided with strategically placed holes for securement of the mounting plate at other positions rotatably offset about the path of the metal stock as illustrated by phantom lines.
The mounting plate 54 and support plate 55 have at their centers respective aligned openings 64 and 65 concentric with the path of the metal stock indicated by the arrow 51. Received in such openings 64 and 65 is a tubular alignment guide 66 secured at an annular flange to the downstream side of the support plate by fasteners 67. The tubular alignment guide 66 has an inner diameter substantially greater than the metal stock to be processed for free passage of the metal stock along the path 51.
As best seen in FIG. 3, the segmental die mechanism 50 comprises a pair of diametrically opposed, large piston-cylinder assemblies 69 which hereinafter are referred to as shaving die actuators. The cylinder 70 of each actuator 69 is rigidly secured by a pair of mounting blocks 71 to the mounting plate 54 by fasteners 72. Each actuator is of double-ended type having a piston rod 73 projecting from opposite ends of the cylinder 70. At its radially outer projecting end, the piston rod 73 has secured thereto an adjustment collar hub 74 by a fastener 75. The hub 74 is externally threaded for threaded receipt of an adjustment collar 76 which is operable to abut the adjacent end of the cylinder 70 to limit radially inward movement of the piston rod 73. The extent of inward movement of the piston rod may be easily adjusted by rotating the collar on the hub. Once adjusted as desired, the collar may be fixed in place by a set screw 77. The collar also may be provided with a gradient as seen at 78 to facilitate adjustment.
At its radially inner end, the piston rod 73 of each actuator 69 is connected to a respective carriage block 80. The carriage blocks 80 are rigidly constrained for radial movement on a slide plate 81 by parallel guide blocks 82. The guide blocks 82 are fixedly secured to the mounting plate 54 by fasteners 83 with the slide plate 81 being clamped flush to the mounting plate 54 by such guide blocks as illustrated. As best seen in FIG. 4, the guide blocks 82 are undercut at their inner sides for receipt of corresponding side flanges on each carriage block. As should now be apparent, extension and retraction of the actuators 69 will move the carriage blocks 80 radially inwardly towards and away from the path 51 of the metal stock with the extent of radially inward movement being precisely determined by the adjustment collars 76.
Each carriage block 80 is provided at its upstream side opposite the mounting plate 54 with a T-shape slot for close mating receipt of the correspondingly T-shape underside of a tool holder 86, the slot and tool holder underside being outlined by broken lines in FIG. 3. In this manner, the tool holder is locked to the carriage block when secured thereto by fasteners. As further seen in FIG. 3, the radially extending stem of the T-shape groove may terminate at a line axially coinciding with the bottom facet of a three sided groove provided in the radially inner face of the tool holder. The sides or facets of the groove are configured to form three sides of an octagonal shape.
At right angles to the side facets of the groove in each tool holder 86, there are provided respective recesses or insets in the upstream side of each tool holder which are sized and shaped to closely accommodate carbide shaving dies 89. Each die is secured in the respective recess by a fastener 90 with a straight cutting edge extending inwardly beyond and parallel to the respective side facet of the groove. Consequently, the dies are located at next adjacent side of an octagon. Also, the bottoms of the recesses and consequently the dies secured flush therewith may be canted to a plane normal to the path of the metal stock to provide a positive or preferably a negative rake. A preferred negative rake angle is 5°.
The exemplary die arrangement seen in FIGS. 3 and 4 is particularly suitable for shaving rod which has been preformed by the preforming die to a twelve-sided (duo decimagon) cross-sectional shape. Consequently, the dies when radially inwardly indexed as seen in FIG. 3 operate to remove surface metal from respective facets of the metal stock. As discussed below, the dies in the segmental die mechanisms in the progressive die stations may be circumferentially offset at 60° angles whereby surface metal is removed from each facet of the metal stock. As will be appreciated, round or otherwise shaped stock also may be passed through the progressive die stations for imparting thereto a twelve-sided cross-sectional shape that may be readily reformed, for example, to a circular shape if desired.
Although not shown, there may be provided at the segmental die mechanism suitable means for applying lubricant-coolant to the metal stock just upstream of the shaving die elements to facilitate the cutting operation. Also, chip breakers may be provided.
As previously indicated, the segmental die mechanisms 51 and 52 in the downstream progressive die stations 19 and 20 are identical to the just described segmental die mechanism 50 in the upstream die station 18. However, such segmental die mechanisms 51 and 52 are circumferentially offset at opposite 60° angles to the segmental die mechanism 50 at the upstream die station as seen in FIG. 2 and also illustrated by the phantom line positions thereof in FIG. 3. In each case, the segmental die mechanisms are mounted in like manner to their respective mounting plates, but each mounting plate is secured to the corresponding support plate at the desired rotated orientation about the path of the metal stock. As illustrated in FIG. 3, the mounting plate 54a at the intermediate station is counterclockwise offset 60° relative to the mounting plate 54 in the upstream die station whereas the mounting plate 54b at the downstream die station is clockwise offset 60°. Consequently, the segmental die mechanisms each operate to shave respective four sides of metal stock having a twelve sided (duo decimagon) cross-sectional shape.
The above described shaving apparatus may be operated by suitable controls to remove surface material from metal stock. Initially, the metal stock is threaded through the apparatus as previously indicated for connection to suitable take-up means 26 which operates to pull the metal stock through the apparatus at a desired processing speed. As the metal stock is drawn through the apparatus, the shaving die actuators 69 at each progressive die station 18, 19, 20 then may be operated automatically to index the shaving dies 89 into the path of the metal stock for removing surface metal from respective sides of the metal stock. Of course, the adjustment collars 76 will already have been adjusted to provide the desired depth of cut being made by the shaving dies.
In the illustrated embodiment, the metal stock as it passes through each segmental die mechanism 50, 51, 52 is rigidly loaded against the shaving dies 89 in each tool holder by respective diametrically opposed shaving dies in the other tool holder. Moreover, the shaving dies are rigidly held against both radially inward and outward movement by high cylinder pressure forces of the shaving die actuators 69 which serve to hold the adjustment collars 76 butted against the cylinders 70. Consequently, the shaving dies are firmly held against oscillatory movement which may otherwise occur in response to variations in encountered resistance as may result by reason of irregular surface defects on the metal stock. If the shaving dies were not rigidly restrained and held against such oscillatory movement, chattering or vibration could result particularly when shallow surface cuts are being made. In this regard, it further is noted that the tool holders and associated components are of heavy duty construction and type for rigid restraint and firm holding of the shaving dies during the shaving operation.
In order to minimize any vibratory movement of the segmental die mechanisms 50-52 longitudinally with respect to the metal stock during the cutting operation, the support plates 55 therefor are rigidly tied together at common elevation with the segmental die mechanisms by tie bars 96 as seen in FIG. 2. The tie bars are secured to mounting blocks 97 fixed to the support plates at respective common sides of the support plates. Also provided at each side of the assembly are inclined tie bars 98 secured between respective tie bars and the platform plate 33 as illustrated. Of course, the lower ends of the support plates are rigidly tied together by way of their securement to the platform plate.
The foregoing die arrangement and operational procedure is merely representative of one of the many ways in which the apparatus may be utilized. Different segmental shaving dies may be employed and mounted in properly configured tool holders for imparting a different cross-sectional shape to the metal stock than that indicated such as round, polygonal and non-round cross-sections for any given application. Also, the number of progressive die stations may be varied as needed.
In addition, other forms of shaving die actuators may be utilized in place of the hydraulic actuators for effecting automatic indexing of the shaving dies. For example, a screw and gear drive may be provided and powered by a reversible electric motor. In order to prevent undesirable vibration of the shaving dies, the drive components should be of no backlash type.
An electric motor driven screw and gear drive would be particularly useful in another application of the apparatus for obtaining precisely controlled movement of the shaving dies as they are progressively indexed into and out of the path of the metal stock for purposes of imparting a desired taper thereto. That is, a continuous length of metal stock may be provided with a multiplicity of tapers over given lengths thereof by moving the shaving dies gradually radially into and out of the metal stock as a function of the linear rate of the metal stock moving through the apparatus. This could provide, for example, surface improved rod for automotive constant rate suspension spring applications. It perhaps should be further noted that provision of the requisite controls is well within the realm of conventional machine control design.
The apparatus also may be operated to effect selective removal of surface defects or imperfections from the metal stock by utilizing the aforementioned flaw detector 22. The flaw detector may be of any suitable type capable of identifying surface defects and generating control signals upon detection of a defect for effecting responsive actuation of the shaving dies as the flawed area of the metal stock passes through the segmental die mechanisms. Consequently, only the flawed surface portions of the metal stock would be removed. One type of flaw detector which may be utilized is sold by Magnetic Analysis Corporation under the designation type 6RT Indicator and Control Unit. The output of such device may be utilized as an input to circuitry which controls operation of the shaving die actuators. Again, the design of the requisite circuitry is well within the realm of conventional machine control design.
Referring now to FIGS. 5 and 6, another form of tool holder and carbide shaving die arrangement is illustrated. Like before, the tool holder 100 has a T-shape underside which fits in a T-shape slot provided in the carriage block 101 at its upstream side, each tool holder being secured to the respective carriage block by a pair of fasteners 102. The tool holders and associated components are identical but diametrically opposed as illustrated.
At their upstream sides adjacent their radially inner ends, the tool holders 100 each are provided with a rectangular-shape recess or inset 105 for receipt of a carbide segmental shaving die 106. The die located in the recess is securely clamped to the tool holder at the slightly inwardly recessed toe of a heel and toe plate 107 secured to the tool holder by a fastener 108. At its heel, the heel and toe plate is forcibly pivoted by the fastener to provide high clamping forces holding the die securely in place and against vibration relative to the tool holder. Preferably, the recess 105 is slightly canted to the path of the metal stock to provide a negative rake to the shaving die preferably at an angle of about 5°.
Each shaving die 106 is provided as by grinding with an arcuate groove 110 at opposite radial faces thereof, the arc of each groove being struck about respective axes extending perpendicular to the planar faces of the shaving die. Each groove preferably is precision ground to form arcuate cutting edges at the intersection of each groove with adjacent respective faces of the shaving die. Consequently, four cutting edges are provided. When one cutting edge becomes worn, one of the other cutting edges may be utilized by either reversing the shaving die and/or turning the shaving die over. Accordingly, the shaving die need not be replaced or reground until all four cutting edges thereon have become worn.
In those applications employing three progressive die stations having segmental die mechanisms rotated at 60° intervals, the radius and length of the shaving die cutting edges usually would be selected to provide a cut over 60° of the metal stock surface when indexed into the path of the metal stock. Consequently, the shaving dies collectively would provide full surface shaving of the metal stock. As a general rule, the shaving dies may have an arcuate cutting length obtained by dividing the number of progressive die stations into 360°. Of course, the segmental die mechanisms in the die stations would be circumferentially offset at corresponding angular intervals to obtain 360° cutting action.
As also seen in FIGS. 5 and 6, a chip breaker 112 may be and desirably is provided at each shaving die 106. The chip breaker has angularly disposed radially inner and outer end portions, the radially outer end portion being secured to an inclined face of the heel and toe plate 107 by fasteners 113. The angle between the portions of the chip breaker coincides with the angle formed between the radially inner face of the heel and toe plate 107 and the upstream face of the shaving die whereby the fastener holds the chip breaker tightly clamped against such radially inner end face and upstream face. As seen in FIG. 6, the chip breaker may have an arcuate radially inner face 114 against which chips removed from the metal stock by the shaving die are broken to prevent long chip streamers. Long chip streamers are to be avoided since their accumulation at the die may require shutting down the machine to effect their removal.
Referring now to FIG. 7 there is illustrated in schematic an additional embodiment of a shaving apparatus according to the invention for imparting a desired surface finish, cross-section and/or profile to metal stock such as rod, wire and the like. As shown, the metal stock 110 taken from a spool, pay-off reel, or other supply 112 is first passed through a straightener 114. Located ahead of the straightener 114 is a snarl switch 116 to shut down the apparatus if a snarl develops in the metal stock 110. After the straightener 114, the metal stock 110 passes through a descaling chamber 118. Preferably, chamber 118 includes a plurality of nozzles which impact the surface of the metal stock 110 with abrasive particules in a water jet at a pressure of at least about 10,000 psi to remove scale, texturize, and remove up to 0.006" of metal from the surface of the metal stock 110. After chamber 118, the metal stock 110 passes through rollers 120 which align and stabilize the metal stock 110. The metal stock 110 then passes through a plurality of progressive die stations 122 like that discussed above in connection with FIG. 1. After passage through die stations 122, the metal stock 110 then passes through another set of aligning and stabilizing rollers 124 and another descaling chamber 126. The metal stock is then fed to a take-up device 128 which may be in the form of a rotatably driven "pull block", although any suitable means may be employed to pull the metal stock 110 through the apparatus at a desired processing speed.
The descaling chambers 118 and 126 are preferably fed by a hydraulic piston pump 130 capable of developing about 40,000 to 150,000 psi water pressure at about 3 to 5 gallons per minute flow rate. The outflow from pump 130 is directed to an abrasive grit particle hopper 132 to supply abrasive particles into the high pressure water stream. Preferably, the particle size of the grit is from about 40 to about 150 mesh. A hydraulic pump 134 is provided to drive the pumps 130. As shown, hydraulic pump 134 may also be utilized as a source of hydraulic power to supply the hydraulic needs of the die stations 122.
It should now be apparent that the invention provides a highly desirable apparatus and method for removing surface metal from metal stock such as rod, wire, etc. Such removal may be effected, for example, at depths of 0.001 to 0.375 inch depth in a single pass through the apparatus at speeds even as high as 1800 linear feet per minute. The machine is capable of forming longitudinal tapers on the metal stock as well as desired transverse of cross-sectional shapes. Among the various advantages afforded by the present invention are: the ability to shave numerous flats on metal stock for subsequent drawing back to round stock or otherwise shaped material; removal of scale or the like from wire or rod thereby to eliminate the need for acid pickling baths and/or mechanical descalers; shaving of wire or rod to remove deep surface imperfections such as seams, laps and decarborization zones; selective shaving of imperfections from wire or rod surfaces in response to detection by a flaw detector placed upstream of the progressive die stations; and continuous shaving of wire or rod from coil to coil.
Although the invention has been shown and described with respect to a preferred embodiment, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification. The present invention includes all such equivalent alterations and modifications, and is limited only by the scope of the following claims.
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An apparatus and method for shaving elongate metal stock such as rod, wire and the like, characterized by the employment of a plurality of progressive die stations each including diametrically opposed segmental dies which are automatically indexed to remove surface imperfections from metal stock, to impart desired cross-sectional shapes to the metal stock and/or to impart desired tapered profiles to the metal stock. The segmental dies at each station are rigidly secured to respective carriages by heel and toe clamps and the carriages are radially advanced and retracted in rigid restraints by hydraulic actuators provided with adjustable mechanical stops which limit inward carriage adavancement. The carriages and hydraulic actuators for each station are mounted on a mounting plate which is securable to an upright support plate at any one of a member of rotated positions. The support plates are fixed at their lower ends to a base structure and tied at their upper ends to adjacent support plates as well as the base structure to eliminate or minimize chatter as the metal stock is continuously advanced through the progressive die stations.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to ladder accessory apparatus, and more particularly pertains to a new and improved ladder extension step apparatus wherein the same is arranged for mounting relative to an associated ladder step for providing an enlarged step area for use by an individual for enhanced stability in use of the organization.
2. Description of the Prior Art
Ladder accessories of various types have been utilized with conventional step ladders for ease of use of the organization relative to various tasks. It is understood that in the use of such step ladder organizations, the compact structure of such a step ladder dictates ladder steps of relatively limited width defined by the predetermined widths of associated ladder legs mounting the ladder steps therebetween, wherein the instant invention sets forth an organization to provide an enlarged step area for use by an individual with a step ladder type structure.
Examples of prior art ladder accessories may be found and exemplified in U.S. Pat. No. 4,222,541 Cillis wherein a ladder tray support attachment includes a support tray with spaced brackets for mounting to a side rail or leg of an associated ladder.
U.S. Pat. No. 4,316,524 to Lapeyre sets forth a ladder structure utilizing a plurality of steps of various sizes, with a first size positioned laterally relative to a second size of ladder steps.
U.S. Pat. No. 4,318,523 Weatherly sets forth a support device mounted for use with hollow rung ladders mounted to studs directed within the hollow rung ladders for providing a support organization for use with various components, such as tools, paint materials, and the like.
As such, it may be appreciated that there continues to be a need for a new and improved ladder extension step apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction and in this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of ladder apparatus now present in the prior art, the present invention provides a ladder extension step apparatus wherein the same is arranged for selective mounting exteriorly of ladder steps of an associated ladder arrangement for enhanced support area for use by an individual. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved ladder extension step apparatus which has all the advantages of the prior art ladder apparatus and none of the disadvantages.
To attain this, the present invention provides a ladder extension member arranged for securement to an associated ladder step of an associated ladder, wherein the organization is dismounted relative to the ladder step for resecurement thereto to provide an extension step. The extension step includes a plurality of "J" shaped support members mounting a planar support web fixedly therebetween, wherein the spaced "J" shaped support members permit capturing of an associated ladder step between the support web and a cavity defined by the "J" shaped support members. A plurality of spaced bottom plates are arranged with slots to effect selective capturing of the associated ladder step therewithin, or reciprocatable to a rear position to permit removal of the organization relative to the ladder step for reorientation of the ladder step thereto. A further unit of the organization includes a plurality of "U" shaped bottom plates, with a step plate mounted thereon, with the step plate including a plurality of "L" shaped bracket members, wherein each bracket member includes a downwardly depending clamping jaw flange, wherein spaced pairs of clamping jaw flanges capture associated ladder legs therebetween to stabilize the unit on a ladder with cylindrical steps formed thereon.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the function specified.
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, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 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.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the 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.
It is therefore an object of the present invention to provide a new and improved ladder extension step apparatus which has all the advantages of the prior art ladder apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved ladder extension step apparatus which may be easily and efficiently manufactured and marketed.
It is further object of the present invention to provide a new and improved ladder extension step apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved ladder extension step apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such ladder extension step apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved ladder extension step apparatus which provides in the apparatus and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved ladder extension step apparatus wherein the same sets forth a compact organization arrange for retrofit relative to an associated ladder organization, wherein the apparatus provides for an enlarged support area for a step for use by an individual.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularly in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of a prior art ladder accessory apparatus.
FIG. 2 is an isometric illustration of the instant invention.
FIG. 3 is an orthographic side view, taken along the line 3--3 of FIG. 2 in the direction indicated by the arrows.
FIG. 4 is an isometric exploded view of the instant invention.
FIG. 5 is an isometric illustration of a modification of the instant invention.
FIG. 6 is an orthographic side view of the modificaton of the instant invention.
FIG. 7 is an isometric exploded illustration of the modification of the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 3-7 thereof, a new and improved ladder extension step apparatus embodying the principles and concepts of the present invention and generally designated by the reference numerals 10 and 10a will be described.
More specifically, the ladder extension step apparatus 10 of the instant invention essentially comprises a ladder assembly, including a forward right ladder leg 11 spaced from a forward left ladder leg 12. The forward right and left ladder legs 11 and 12 mount a series of spaced parallel planar ladder steps 15 orthogonally therebetween, with the ladder steps 15 arranged in a parallel spaced relationship, in a manner as illustrated in FIG. 1 for example. The ladder assembly includes a rear right ladder leg 13 and a rear left ladder leg 14 providing stability to the organization, wherein the ladder legs are mounted to a ladder top plate 16. The extension assembly 17 of the instant invention is mounted to one of the ladder steps 15 that includes spaced parallel support members defined by a right "J" shaped top support member 18 spaced from and parallel a left "J" shaped top support member 19. Each of the "J" shaped top support members 18 and 19 are formed by a first plate web 20 defined by a first length orthogonally mounted to a second plate web 21 defined by a second length, wherein the second length is substantially equal to a first height defined by each of the planar ladder steps 15. The planar ladder steps 15 are further defined by a first width measured parallel to each of the ladder legs 11 and 12. The second plate web 21 is then orthogonally mounted to a third plate web 22 defined by a third length, wherein the third length is less than that of the first width defined by each of the planar ladder steps 15, wherein the second and third plate webs 21 and 22 are define an "L" shaped bracket to receive a forward edge of each associated support web 24, wherein the third plate web 22 is arranged below and parallel the first plate web 20 and defines the third length substantially less than the first length. Each of the first plate webs 20 includes a plurality of spaced circular apertures directed therethrough defined by a predetermined spacing therebetween. The planar support web 24 includes a plurality of support web openings defined by respective right and left support web openings 25 and 26 respectively positioned adjacent respective right and left side edges of the planar support web 24, wherein each of the web openings 25 and 26 are spaced apart the equal predetermined spacing to receive an externally threaded rod 31 through each pair of openings defined by a spaced circular aperture 23 and an associated underlying web opening, as illustrated in FIG. 4.
Respective right and left bottom plates 27 and 28 are mounted to the planar support web 24 to a bottom surface thereof spaced from and parallel each respective "J" shaped top support member 18 and 19, wherein each of the right and left bottom plates 27 and 28 include a plurality of respective slots defined by spaced right elongate slots 29 and spaced left elongate slots 30. The spaced right elongate slots 29 are positioned underlying the respective right support web openings 25, with the spaced left elongate slots 30 positioned below the left support web openings 26 to receive a lower terminal end of each of the threaded rods 31. Each threaded rod 31 includes a threaded rod enlarged head member 31a defined by a further diameter greater than a predetermined diameter of the circular apertures 23 to maintain each of the threaded rods relative to the assembly. An internally threaded fastener 32 is threadedly secured to each threaded rod below a respective slot of the spaced elongate slots 29 and 30 to permit loosening of each of the bottom plates 27 and 28 to permit each bottom plate to reciprocate from a first extended position, wherein a forward edge of each of the bottom plates 27 and 28 extends below a portion of the associated ladder step 15 to a second position, wherein each of the right and left bottom plates 27 and 28 are positioned in orientation, wherein each bottom plate forward edge is positioned below the ladder step 15. In this manner when the bottom plates are retracted to the second position, the ladder step 15 may be removed relative to the step cavity 34 defined within each "J" shaped top support member, the associated support web 24, and an associated bottom plate. When the bottom plates 27 and 28 are in the first position, such as illustrated in FIG. 3, the associated ladder step 15 is captured within the step cavity 13, whereas upon retraction of the bottom plates to a second position, the ladder step 15 may be removed relative to the cavity for permitting repositioning of the extension assembly in orientation one hundred eighty degrees rotated relative to the configuration, as illustrated in FIG. 2, to provide an extending orientation of the planar support web 24 exteriorly of the associated ladder step 15, if desired. Alternatively, the extension assembly 17 may be positioned as illustrated, wherein the extended platform is directed between the forward and rear ladder legs for use as a support platform.
FIGS. 5-7 illustrate a modified ladder extension step apparatus 10a for use with ladders utilizing cylindrical step members 13 arranged orthogonally at equally spaced intervals between the forward right and left ladder legs 11 and 12. It should be noted that the right and left ladder legs 11 and 12 are each defined by a predetermined width. A step plate 35 is defined by a predetermined length equal to a predetermined length between the right and left ladder legs 11 and 12, and include respective right and left step plate side edges 36 and 36a respectively. A "U" shaped bottom plate 37 is mounted to a bottom surface of the step plate 35 adjacent the right and left side edges 36 and 36a, and formed with a central concave cavity 38, wherein the concave cavity 38 of each "U" shaped bottom plate 37 is in a coaxially aligned relationship relative to one another, and includes respective forward and rear leg wings 39 and 40 that are coplanar and aligned relative to one another and are formed with forward and rear leg wing apertures 41 and 42 respectively and spaced apart a predetermined distance. A plurality of step plate apertures 43 are directed through the step plate 35 adjacent the right and left side edges to position a leg wing aperture in alignment with an associated step plate aperture. A plurality of mounting brackets defined by a respective forward and rear mounting bracket 44 and 45 defining a pair of mounting brackets are oriented to position a pair of such mounting brackets adjacent each side edge of the step plate 35. Each of the mounting brackets 44 and 45 includes a first bracket leg 46 integrally and orthogonally mounted to a second bracket leg 47 defining an "L" shaped coplanar top surface oriented in a first plane, wherein an enclosed slot 48 is formed within each first bracket leg 46 adjacent a respective second bracket leg 47 to receive an associated fastener rod 31 therethrough. Each threaded fastener rod 31 is defined by a predetermined diameter, and includes an enlarged head 31a positioned above each associated slot 48 to secure each of the brackets 46 and the "U" shaped bottom plates 37 together relative to the step plate 35. Each second bracket leg 47 includes a clamping jaw flange 49 oriented in a second plane, wherein the second plane defines an acute angle relative to the first plane and wherein the clamping jaw flanges are spaces apart a distance equal to the predetermined width of each ladder leg to capture a respective ladder leg between a respective pair of the forward and rear mounting brackets 44 and 45. In this manner, a cylindrical step member 33 is positioned within the aligned "U" shaped concave cavities 38, wherein rotation of the organization is prevented by the clamping flanges 49 positioned exteriorly of and to capture a respective ladder leg 11 or 12 therebetween. It should be noted that the enclosed slots 48 are maintained a longitudinally aligned orientation relative to one another and are oriented generally parallel to a side edge of the associated step plate 35.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A ladder extension member is arranged for securement to an associated ladder step of an associated ladder, wherein the organization is dismounted relative to the ladder step for resecurement thereto to provide an extension step. The extension step includes a plurality of "J" shaped support members mounting a planar support web fixedly therebetween, wherein the spaced "J" shaped support members permit capturing of an associated ladder step between the support web and a cavity defined by the "J" shaped support members. A plurality of spaced bottom plates are arranged with slots to effect selective capturing of the associated ladder step therewithin, or reciprocatable to a rear position to permit removal of the organization relative to the ladder step for reorientation of the ladder step thereto.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims, under 35 U.S.C. §119(a), the benefit of the filing date of Korean Patent Application No. 10-2005-0136237 filed on Dec. 31, 2005, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a process for manufacturing a porous carbon nanofiber only by heat treatment using camphor, a volatile compound, without taking an activation step and the carbon nanofiber manufactured thereby.
[0004] 2. Background Art
[0005] Conventionally, a carbon nanofiber has been manufactured by a method such as electric spinning, laser vapor deposition, plasma chemical gas phase vapor deposition, thermochemical vapor deposition, gas phase synthesis and the like. Of these, in the electric spinning method, after carbon nanofiber precursor material is dissolved in an organic solvent, a high voltage is applied between the jet nozzle of a syringe and the collector to continuously form a carbon nanofiber precursor in the dispersed state, and nanofiber is collected in the form of non-wovens in the collector. Since the thus-obtained fiber has a thermoplastic property, it is impossible to be heat-treated at a high temperature, higher than the melting point of the precursor material. To prepare a thermosetting fiber, infusible stabilized fiber is obtained through an oxidative stabilization process and it is subject to a carbonization process at a temperature of from 500° C. to 1500° C. to obtain a carbon nanofiber. The electric spinning method can manufacture a carbon nanofiber with a diameter of less than 1 μm while a solution spinning or melt spinning method can manufacture a carbon fiber with a diameter of 10 to 20 μm.
[0006] In order to manufacture a conventional carbon nanofiber, after oxidative stabilization, a gas containing water vapor, carbon dioxide, air and so on is passed and an activation process at a temperature of from 500° C. to 1500° C. is performed. Alternatively, after carbonization at a high temperature, KOH or NaOH is mixed before a chemical activation process at a high temperature is performed.
[0007] However, in case of performing the activation process using a gas containing water vapor, carbon dioxide, air and so on, physical properties of the carbon nanofiber can vary depending on the contents of the water vapor, carbon dioxide, air and so on in the gas and the size of the reaction furnace. In addition, since distribution of such active material contained in the gas is not uniform, process reproducibility decreases.
[0008] In the chemical activation process using various salts such as KOH or NaOH, since carbon nanofiber and the salts are sufficiently mixed to be heat-treated, it is difficult to be used in a continuous process and mass production, and an additional process for removal of mixed salts, after activation, is required. Furthermore, as salts, active materials, cause reaction furnace to be corroded after heat treatment. Thus, commercial application is difficult.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention has been made in an effort to provide an improved process for manufacturing a porous carbon nanofiber by heat treatment using a volatile organic compound without an activation step and a new porous carbon nanofiber prepared by the same.
[0010] In one aspect, the present invention provides a process for manufacturing a carbon nanofiber comprising: (a) mixing a carbon nanofiber precursor and camphor in a solvent to prepare a solution; (b) electric spinning the solution to obtain a nanofiber; (c) oxidative stabilizing the nanofiber; and (d) carbonizing the oxidative stabilized nanofiber, wherein camphor is volatilized to form micropores in the oxidative stabilization and carbonization.
[0011] Preferably, the camphor content is from 100 to 200 wt % of the carbon nanofiber precursor. Also preferably, the carbon nanofiber precursor is at least one selected from the group consisting of polyacrylonitrile (PAN), cellulose and polyimide (PI). Suitable solvent may include, but not limited to, N,N-dimethylformamide (DMF), N,N-dimethylacetamide, tetrahydrofuran and the like.
[0012] In a preferred embodiment, the oxidative stabilization process may comprise a step where nanofiber is heated from a normal temperature to the final temperature of 250° C. to 300° C. at the elevating rate of 0.5° C./min to 2° C./min to obtain an infusible stabilized fiber.
[0013] In another aspect, the present invention provides a carbon nanofiber manufactured by the processes described above. Preferably, the size of micropores is from 0.5 nm to 50 nm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These, and other features and advantages of the invention, will become clear to those skilled in the art from the following detailed description of the preferred embodiments of the invention rendered in conjunction with the appended drawings in which like reference numerals refer to like elements throughout, and in which:
[0015] FIG. 1 represents a diagram showing an electric radiation apparatus for manufacturing a carbon nanofiber according to a preferred embodiment of the present invention;
[0016] FIG. 2 represents a flow chart showing a process for manufacturing a porous carbon nanofiber according to a preferred embodiment of the present invention;
[0017] FIGS. 3 a and 3 b represent microscopic photographs of a carbon nanofiber made of PAN with 200 wt % of camphor added; and
[0018] FIGS. 4 a and 4 b represent a nitrogen adsorption isothermal graph of carbon nanofiber made of PAN with 200 wt % of camphor added and a table analyzing micropores properties calculated by α-s method, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Reference will now be made in detail to the preferred embodiment of the present invention, examples of which are illustrated in the drawings attached hereinafter, wherein like reference numerals refer to like elements throughout. The embodiments are described below so as to explain the present invention by referring to the figures.
[0020] FIG. 1 shows an electric radiation apparatus for manufacturing a carbon nanofiber according to a preferred embodiment of the present invention. FIG. 2 represents a flow chart showing a process for manufacturing a porous carbon nanofiber according to a preferred embodiment of the present invention.
[0021] To manufacture a porous carbon nanofiber according to the present invention, a carbon nanofiber precursor for electric spinning, a solvent and camphor are mixed to prepare a polymeric solution. After camphor of 100 to 200 wt % based on polyacrylonitrile as a carbon nanofiber precursor is added to DMF (N,N-dimethylformamide) as a solvent and is dissolved. Polyacrylonitrile as a carbon nanofiber precursor polymer is then added. After these two materials are dissolved in the solvent, they are subject to ultrasonic treatment for 10 to 20 hours so that camphor is uniformly dispersed in polyacrylonitrile, and a polymeric solution is prepared. The polymeric solution is brought to the syringe and fiber is made using the electric spinning apparatus as shown in FIG. 1 . High voltage of 5 kV to 35 kV is applied between the jet nozzle and the collector, and the applied voltage is controllable through a voltage device. In a preferred embodiment, 20 kV of voltage is applied through a voltage device. Carbon nanofiber precursor jetted by the jet nozzle is continuously collected as form of nonwovens on the collector. The nanofiber prepared in this way is placed in an electric furnace to which air can be provided to make thermosetting fibers and is heated from a normal temperature to the final temperature of 250° C. to 300° C. at a rate of 0.5° C./min to 2° C./min to obtain an infusible stabilized fiber through an oxidative stabilization process.
[0022] The thus-prepared thermosetting fiber can be brought through a carbonization process at a temperature of 500° C. to 1500° C. in an inactive atmosphere or in a vacuum state to obtain a carbon nanofiber. Since the temperature of 250° C. to 300° C., which is the final temperature of the oxidative stabilization process, is beyond the boiling point of camphor, which is about 200° C., most of the camphor is released from the nanofiber to form micropores at the surface of the nanofiber. Also, it is surrounded with polyacrylonitrile so that any camphor that has not been released in the oxidative stabilization process and is present in the polyacrylonitrile is all released in the carbonization treatment process at a high temperature, and a carbon nanofiber having micropores at its surface is manufactured.
[0023] The diameter of the carbon nanofiber obtained in this way ranges from 50 nm to 300 nm, the specific surface area is 500 m 2 /g, and the size of the micropores ranges from 0.5 to 50 nm. The specific surface area of carbon nanofiber and the size of the micropores can be adjusted depending on the camphor content and the ultrasonic treatment time.
[0024] According to the present invention, a porous carbon nanofiber having various sizes of surface area can be manufactured through an oxidative stabilization process and a carbonization process of nanofiber made by electric spinning method without an activation process.
[0025] FIGS. 3 a and 3 b are microscopic photographs of a porous carbon nanofiber after the oxidative stabilization process and carbonization process. The positions of camphor removal can be recognized as those projected in white color, representing less crystallization than other positions. In addition, the white projected part is so uniformly distributed over the surface of the fiber that it can be uniformly carried when used as a catalyst carrier.
[0026] FIG. 4 a shows a nitrogen adsorption isothermal graph of the carbon nanofiber manufactured after the oxidative stabilization process and the carbonization process according to the present invention. FIG. 4 b represents a table analyzing the properties of the micropores formed in the carbon nanofiber using the α-s method in the case of fiber made of a polymeric solution containing polyacrylonitrile and 200 wt % of camphor.
[0027] As described above, according to the preferred embodiments of the present invention, no additional materials required for, for instance, gas activation and chemical activation. Also, since the porous carbon nanofiber is manufactured through carbonization after oxidative stabilization, a continuous process and/or a mass production can be performed. In addition, since camphor removal position is projected in the white color of less crystallization than other positions and is the porous structure uniformly distributed over the whole surface of the fiber, it can be carried uniformly when used as a catalyst carrier. Furthermore, the size and the specific surface area of micropores can be controlled based on the camphor content and the ultrasonic treatment time so that carbon nanofibers having micropores can have specific surface area which is large relative to the volume. As a result, it is applicable to various industrial fields such as supercapacitors, fuel cells, adsorptive materials and the like.
[0028] The invention has been described in detail with reference to preferred embodiments thereof. However, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
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The present invention provides a process for manufacturing a carbon nanofiber comprising: (a) mixing a carbon nanofiber precursor and camphor in a solvent to prepare a solution; (b) electric spinning the solution to obtain a nanofiber; (c) oxidative stabilizing the nanofiber; and (d) carbonizing the oxidative stabilized nanofiber, wherein camphor is volatilized to form micropores in the oxidative stabilization and carbonization. The present invention also provides a carbon nanofiber manufactured by the same.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present patent application/patent claims the benefit of priority of co-pending U.S. Provisional Patent Application No. 62/317,138, filed on Apr. 1, 2016, and entitled “COMPUTER IMPLEMENTED DELIVERY OF A MOTIVATIONAL INTERVENTION TO ADDRESS HEAVY ALCOHOL CONSUMPTION AND OTHER DISORDERS,” the contents of which are incorporated in full by reference herein.
STATEMENT OF GOVERNMENT SPONSORED RESEARCH AND/OR DEVELOPMENT
[0002] The present invention was made with Government support by the Agency for Healthcare Research and Quality (AHRQ), Award No. 1R21 HSO23875-01. Accordingly, the Government has certain rights in the present invention.
FIELD OF THE INVENTION
[0003] The present invention relates generally to an alcohol and drug intervention system and method. More specifically, the present invention relates to an alcohol and drug intervention system and method that periodically queries and/or messages a user about their alcohol and drug use. This periodicity may be random, scheduled, or prompted by a geofencing application or the like. The intervention system includes a server component and a mobile application component executed on a wireless mobile device or the like. Optionally, the intervention system also includes a physical testing device, such as a breathalyzer, a fluid tester, or the like, that is coupled to the wireless mobile device. The intervention system utilizes robust data security technologies and implements novel archiving and, optionally, reporting features.
BACKGROUND OF THE INVENTION
[0004] Alcohol and drug use among college students is a national public health concern, resulting in significant consequences among college students 18-24 years old. College administrators continually seek to reduce heavy drinking and drug use and mitigate these consequences, often at great effort and expense. Multiple intervention approaches are utilized, including the dissemination of public awareness information and online and in person coaching and therapy, the latter of which is typically confidential. Many of the packaged intervention tools are utilized at the over 4,000 public and private institutions of higher learning in the United States. These intervention tools are typically subscription based and the cost structure is often defined by student enrollment. For example, some of the intervention tools cost between $1,000 and $15,000 per year, creating a market of approximately $60 million per year.
[0005] Because today's students are digital natives and mobile devices are ubiquitous among them, a mobile application designed to moderate alcohol and drug use could greatly help and overcome logistical and financial barriers in higher education.
BRIEF SUMMARY OF THE INVENTION
[0006] Thus, in various exemplary embodiments, the present invention provides a mobile application that motivates college students (and potentially others) to reduce excessive drinking and drug use, and the associated harms, by translating face-to-face brief motivational interventions (BMIs) into a digital format utilizing a virtual coach, motivational interviewing, personalized feedback, educational games, and user tools (e.g. goal setting features, harm reduction strategies, drink/drug logs, resources, etc.). Based on an inputted user profile, the intervention system periodically queries and/or messages a user about their alcohol and drug use. This periodicity may be random, scheduled, or prompted by a geofencing application or the like. The intervention system includes a server component and a mobile application component executed on a wireless mobile device or the like. Optionally, the intervention system also includes a physical testing device, such as a breathalyzer, a fluid tester, or the like, that is coupled to the wireless mobile device. The intervention system utilizes robust data security technologies and implements novel archiving and, optionally, reporting features. As a whole, the intervention system periodically assess the user's status in terms of alcohol or drug use and provides appropriate coaching. The coaching is based on motivational interviewing and incorporates both user persuasion and health research. Informational and interventional output, trivia, games, a blood alcohol content (BAC) calculator, and a log book are all provided, for example, and user feedback allows for a great deal of personalization.
[0007] In one exemplary embodiment, the present invention provides an alcohol and drug intervention system, comprising: a server component; and a mobile application component wirelessly coupled to the server component; wherein the server component and the mobile application component are collectively operable for, in an interactive manner, receiving input from a user and presenting the user with output based on the input received from the user, wherein the input received from the user comprises one or more of personal information, activity information, and activity related to alcohol and/or drug use, and wherein the output presented to the user comprises one or more of coaching information and counseling information. The server component comprises a processor executing one or more application programming interfaces and a database. The mobile application component comprises one or more of a mobile telephone, a personal digital assistant device, and a tablet device. The server component and the mobile application component are further collectively operable for presenting trivia game questions to the user and receiving trivia game answers from the user and adjusting one or more of the coaching and counseling information based on the trivia game answers received from the user. The server component and the mobile application component are further collectively operable for implementing a blood alcohol content calculator. Optionally, the system further comprises a geofencing component operable for determining a location of the user and tailoring requested inputs and presented outputs based thereon. Optionally, the system still further comprises an alarm component operable for one or more of triggering and alarm and alerting a third party if the input received from the user indicates that user alcohol and/or drug use has exceeded a predetermined threshold. Optionally, the system still further comprises a testing device coupled to the mobile application component and adjusting one or more of the coaching and counseling information based on results obtained from the testing device. The testing device comprises one or more of a breathalyzer, a saliva testing device, a blood testing device, a urine testing device, a facial expression analyzer. Optionally, the server component and the mobile application component are further collectively operable for blinding an identity of the user such that the user is anonymous when interacting with the mobile application component.
[0008] In another exemplary embodiment, the present invention provides an alcohol and drug intervention method, comprising: providing a server component; and providing a mobile application component wirelessly coupled to the server component; wherein the server component and the mobile application component are collectively operable for, in an interactive manner, receiving input from a user and presenting the user with output based on the input received from the user, wherein the input received from the user comprises one or more of personal information, activity information, and activity related to alcohol and/or drug use, and wherein the output presented to the user comprises one or more of coaching information and counseling information. The server component comprises a processor executing one or more application programming interfaces and a database. The mobile application component comprises one or more of a mobile telephone, a personal digital assistant device, and a tablet device. The server component and the mobile application component are further collectively operable for presenting trivia game questions to the user and receiving trivia game answers from the user and adjusting one or more of the coaching and counseling information based on the trivia game answers received from the user. The server component and the mobile application component are further collectively operable for implementing a blood alcohol content calculator. Optionally, the method further comprises providing a geofencing component operable for determining a location of the user and tailoring requested inputs and presented outputs based thereon. Optionally, the method still further comprises providing an alarm component operable for one or more of triggering and alarm and alerting a third party if the input received from the user indicates that user alcohol and/or drug use has exceeded a predetermined threshold. Optionally, the method still further comprises providing a testing device coupled to the mobile application component and adjusting one or more of the coaching and counseling information based on results obtained from the testing device. The testing device comprises one or more of a breathalyzer, a saliva testing device, a blood testing device, a urine testing device, a facial expression analyzer. Optionally, the server component and the mobile application component are further collectively operable for blinding an identity of the user such that the user is anonymous when interacting with the mobile application component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like system components/method steps, as appropriate, and in which:
[0010] FIG. 1 is a mobile application screenshot of an exemplary coaching introduction and query screen associated with the intervention system of the present invention;
[0011] FIG. 2 is a mobile application screenshot of an exemplary coaching output screen associated with the intervention system of the present invention, distilling collected and archived information into statistical conclusions;
[0012] FIG. 3 is a mobile application screenshot of an exemplary trivia game screen associated with the intervention system of the present invention;
[0013] FIG. 4 is a schematic diagram illustrating one exemplary embodiment of the structural architecture of the intervention system of the present invention, including a server component, a mobile application component, and, optionally, a pluggable testing device;
[0014] FIG. 5 is a mobile application screenshot of an exemplary authentication screen associated with the intervention system of the present invention;
[0015] FIG. 6 is a mobile application screenshot of an exemplary coaching output screen associated with the intervention system of the present invention;
[0016] FIG. 7 is a mobile application dual screenshot of an exemplary coaching output screen associated with the intervention system of the present invention;
[0017] FIG. 8 is a mobile application screenshot of an exemplary coaching output screen associated with the intervention system of the present invention;
[0018] FIG. 9 is a mobile application screenshot of an exemplary BAC calculator screen associated with the intervention system of the present invention;
[0019] FIG. 10 is a mobile application screenshot of an exemplary learning resource screen associated with the intervention system of the present invention;
[0020] FIG. 11 is a mobile application screenshot of an exemplary contact list screen associated with the intervention system of the present invention;
[0021] FIG. 12 is a mobile application screenshot of an exemplary trivia game screen associated with the intervention system of the present invention;
[0022] FIG. 13 is a mobile application screenshot of an exemplary trivia game scoreboard screen associated with the intervention system of the present invention; and
[0023] FIG. 14 is a mobile application screenshot of an exemplary trivia game feedback screen associated with the intervention system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Again, in various exemplary embodiments, the present invention provides a mobile application that motivates college students (and potentially others) to reduce excessive drinking and drug use, and the associated harms, by translating face-to-face BMIs into a digital format utilizing a virtual coach, motivational interviewing, personalized feedback, educational games, and user tools (e.g. goal setting features, harm reduction strategies, drink/drug logs, resources, etc.). Based on an inputted user profile, the intervention system periodically queries and/or messages a user about their alcohol and drug use. This periodicity may be random, scheduled, or prompted by a geofencing application or the like. The intervention system includes a server component and a mobile application component executed on a wireless mobile device or the like. Optionally, the intervention system also includes a physical testing device, such as a breathalyzer, a fluid tester, or the like, that is coupled to the wireless mobile device. The intervention system utilizes robust data security technologies and implements novel archiving and, optionally, reporting features. As a whole, the intervention system periodically assess the user's status in terms of alcohol or drug use and provides appropriate coaching. The coaching is based on motivational interviewing and incorporates both user persuasion and health research. Informational and interventional output, trivia, games, a BAC calculator, and a log book are all provided, for example, and user feedback allows for a great deal of personalization.
[0025] FIG. 1 is a mobile application screenshot of an exemplary coaching introduction and query screen associated with the intervention system of the present invention.
[0026] FIG. 2 is a mobile application screenshot of an exemplary coaching output screen associated with the intervention system of the present invention, distilling collected and archived information into statistical conclusions.
[0027] FIG. 3 is a mobile application screenshot of an exemplary trivia game screen associated with the intervention system of the present invention.
[0028] FIG. 4 is a schematic diagram illustrating one exemplary embodiment of the structural architecture of the intervention system 10 of the present invention, including a server component 12 , a mobile application component 14 , and, optionally, a pluggable testing device 16 .
[0029] The server component 12 is designed and hosted on a managed network server that resides in a data center or the like. The server uses a Java and Spring architecture, for example. The server provides storage for all mobile application data, all survey and web functions, and application programming interfaces (APIs) required to interface with the mobile application. All user and other data is stored on the server in a MySQL database or the like. Interfacing with the database is performed using the Hibernate framework or the like. Stored data items include, but are not limited to, user profile information, user survey responses, user customized feedback, user strategies, trivia and game categories/questions/scoreboards, user customized conversations, user responses generated through the mobile application, other statistics collected through the mobile application, etc. Services provided, but are not limited to, user surveys, user feedback, push notifications, background job management, storage services, APIs, etc. User surveys include, but are not limited to demographic surveys, AUDIT surveys, DDQ surveys, B-YAACQ surveys, etc. The user feedback function provides customized feedback to the user based on information provided in the user surveys. The background job function is a background job on the server that executes periodically (every thirty minutes, for example), performing queries on the databases to identify users to contact and to send push notifications to. The push notifications function sends push notifications to users to alert the users to different components and to ask users specific questions based on the customized conversation. Finally, the APIs include user authentication (login, logout, etc.), user profiles (get user profile, update user profile, etc.), coaching (get coaching list, set answer to coaching message, update coaching message open list, etc.), user feedback (get user feedback, etc.), trivia (get trivia questions, set user trivia answers, get trivia scoreboard list, etc.), winning rounds (set user winning rounds time, get winning rounds scoreboard list, etc.), push notifications (register user device token, unregister user device token, etc.), etc.
[0030] Of note, the optional geofencing functionality allows the mobile application to use GPS or near field location information to identify where a user is at a given time and, if that location is determined to be an “at risk” location (based on publicly available information or a prior tag), such as a bar or a known acquaintance's residence, provide the user with immediate event prompted coaching. This event prompted coaching may be preceded by a user alert or the like.
[0031] The mobile application component 14 is developed for and iOS or Android framework, for example, using Swift or the like. The mobile application communicates with the server using the developed API services and through push notifications. The mobile application maintains a local database (Core Data) that is used to store, user profiles, user session information, and coaching interactions with users.
[0032] Further, the optional pluggable testing device 16 can include a breathalyzer, a saliva testing device, a blood testing device, a urine testing device, a facial expression analyzer, or the like that is coupled to the data port or the headphone jack of the mobile device. The user may be periodically prompted to use this pluggable testing device 16 , such as at regular intervals, responsive to a given questionnaire, at the direction of the geofencing application, etc., and, depending upon the testing results, the user is then provided with coaching tailored to their given state of intoxication. Appropriate alarms and SOS messages may also be delivered if it is determined that this state of intoxication is severe or life threatening. Finally, the geofencing application and/or the pluggable testing device 16 may be activated if and when it is determined that the user has entered a vehicle, for example—the intervention application then providing appropriate coaching, alrets, SOS messages, etc.
[0033] FIG. 5 is a mobile application screenshot of an exemplary authentication screen associated with the intervention system of the present invention. Appropriate credentials are provided to users during a registration process.
[0034] FIG. 6 is a mobile application screenshot of an exemplary coaching output screen associated with the intervention system of the present invention. Interaction with a user is provided through customized messages that are delivered to the user. These messages are preferably chained and depend upon user feedback, drinking history, and assessed progress, for example.
[0035] FIG. 7 is a mobile application dual screenshot of an exemplary coaching output screen associated with the intervention system of the present invention. Messages are blinded and displayed once a user clicks on them. This enables the provider to ensure that the user is actually reading the provided messages and progressing.
[0036] FIG. 8 is a mobile application screenshot of an exemplary coaching output screen associated with the intervention system of the present invention. A user is able to select a given virtual coach from a list of provided coaches, for example.
[0037] FIG. 9 is a mobile application screenshot of an exemplary BAC calculator screen associated with the intervention system of the present invention. Preferably, this BAC calculator is fully interactive and syncs with the other coaching functionalities.
[0038] FIG. 10 is a mobile application screenshot of an exemplary learning resource screen associated with the intervention system of the present invention.
[0039] FIG. 11 is a mobile application screenshot of an exemplary contact list screen associated with the intervention system of the present invention. This provides the user with website urls and phone numbers for places that can provide the user with academic and health counseling assistance.
[0040] FIG. 12 is a mobile application screenshot of an exemplary trivia game screen associated with the intervention system of the present invention.
[0041] FIG. 13 is a mobile application screenshot of an exemplary trivia game scoreboard screen associated with the intervention system of the present invention. User identities are anonymized to ensure user privacy.
[0042] FIG. 14 is a mobile application screenshot of an exemplary trivia game feedback screen associated with the intervention system of the present invention.
[0043] Further, user authentication is provided using a username and password or through the provisioning of a barcode token that can be scanned by the mobile device camera to pass on the authentication token to the user. This authentication approach enables the user to login without the need to remember a username and password. It also allows the intervention councilor to be able to verify that the user is authenticated successfully.
[0044] The application does not expose the user identity and encrypts the user's information when stored in the database and in transit. Any user interactions or text input is analyzed to ensure that the submitted data does not expose the user's identity. This is done by building data mining text models that compute differential privacy metrics that validate that the user identity before and after making the post have the same exposure values.
[0045] Optionally, the mobile application provides several educational and awareness tools to the user. The user is provided with several trivia features that enhances the user's awareness of alcohol consumption in a fun and interesting way. The mobile application provides a tapping game that tests the user's attention to ensure that the user is not intoxicated and is able to focus. The user is asked to tap on several figures at specific times and time delays. The time delays are used to estimate the user's attention.
[0046] A student can virtually interact with the MI Coach engine or otherwise engage in games/activities in a virtual setting using a virtual reality device. A wearable biosensor device can be incorporated to provide biodata measures, including heart rate, respiratory rate, and skin temperature, for example. The information is used to identify a relaxation response to a virtual reality video, for example. A virtual game can be used to expose users to alcohol triggers and make drinking seem unpleasant. The virtual reality feature will reduce metabolic activity in the limbic system to train the brain to pay less attention to alcohol related stimuli, thus reducing consumption. The participants can play the sessions 10-15 minutes/day 4-5× week, for example. Participants can also exposed to different scenarios by the National Highway Transportation Safety Administration (NHTSA) that target millennials. Within the game, the user is exposed to alcohol situations then chooses whether to drive home; with the resulting consequences.
[0047] With the smartphone integrated breathalyzer, you breathe into the breathalyzer and the information is sent to your phone and can be found in the app to track participants daily drinking. It connects to your phone via Bluetooth. This will allow for photo/location-verified and time-stamped results with random testing. The information can also be integrated with the coach engine to redirect the intervention and messages. The BAC Track would have a normal sized breathalyzer which has police-grade Xtend Fuel Cell Sensors and one that is a keychain which uses a MicroCheck sensor.
[0048] The present invention, as a brief motivational intervention, is rooted in motivational interviewing and ecological momentary interventions—all approaches that can assist students in managing a myriad of issues that are known to impact college students' health, wellness, and safety. For instance, the present invention could be adapted to assist college students in quitting tobacco use, in achieving nutrition and exercise goals, or effectively managing stress—all issues that data show impact students' ability to succeed academically and co-curricularly. Use of a Fitbit wearable biosensor device to tract daily activities, can send reminders to move, and can track type of exercise and provides biodata measures including heart rate, respiratory rate, and skin temperature.
[0049] While the present invention has been designed to intervene specifically with college student populations, it is conceivable that this intervention could be adapted to address alcohol use (and possibly other issues such as PTSD, etc.) among military personnel. While the core concepts of being brief motivational and ecological momentary interventions, as well as overall architecture of the app would remain sound, the app could be appropriately adapted for military personnel (e.g., use of military jargon and acronyms, incorporating elements of military command structure and culture, etc.).
[0050] Although the present invention is illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention, are contemplated thereby, and are intended to be covered by the following non-limiting claims.
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An alcohol and drug intervention system and method, comprising: a server component; and a mobile application component wirelessly coupled to the server component; wherein the server component and the mobile application component are collectively operable for, in an interactive manner, receiving input from a user and presenting the user with output based on the input received from the user, wherein the input received from the user comprises one or more of personal information, activity information, and activity related to alcohol and/or drug use, and wherein the output presented to the user comprises one or more of coaching information and counseling information. Optionally, the system further comprises a testing device coupled to the mobile application component and adjusting one or more of the coaching and counseling information based on results obtained from the testing device.
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FIELD OF THE INVENTION
This invention relates to a discontinuance device for a central reserve. It finds applications in the field of road technology and more especially in the technique of carriageway separation.
BACKGROUND OF THE INVENTION
The carriageway separation devices used currently can be classed into two large groups in relation to their behaviour in case of shock.
The first group exhibits a minimum deformation in case of shock and tends to send the vehicle back towards its carriageway. The separators belonging to this group are therefore relatively rigid or semi-rigid and are generally anchored to the ground and/or made of very massive elements. This separator group is the most used and comprises the concrete wall or concrete separator and the metal guard anchored to the ground or single or double lane rail made of supports driven into the ground, spacers and sliding elements.
The second group, conversely, tends to move in case of shock in order to absorb the energy of the shock. The separators of such group are deformed is and/or move therefore towards the opposite carriageway where they are installed as a central reserve over a distance depending on the conditions of the impact. These separators are generally used in temporary installations, building sites for example, or in areas where the deformation of the separator is not of paramount importance, i.e. areas where the central reserve is wide. Standards have been defined regarding the retention capacities of both these separators groups.
Here, the separators of the first group are considered more particularly; they are generally intended for occupying their long-term position or definitively between the carriageways. We shall use the term permanent separator throughout to designate them.
To enable communications through the central reserves comprising permanent separators, the said separators are discontinued, for example in the case of a highway, every two kilometers or so. At the corresponding places or communication zones, the separators are removable. However, for safety to be ensured throughout the highway, the retention capacity of the separators, at right angle to the said communication zone, must be sufficient and ideally with the same retention level or, still, equivalent to that of the upstream and downstream permanent separators. In known devices, opening easiness and rapidity are reverse functions of the retention capacity because of the presence of the anchoring system to the ground and/or the weight of the separators. If the retention capacity is smaller, the corresponding zone must be as short as possible and must therefore be arranged on a portion of the highway that does not exhibit any particular risk of cars losing control. Still, if for an emergency passage, the communication zone need only be a few meters wide, this communication zone must be a ten-meter wide for the traffic to be diverted from one side of the central reserve to the other. Besides, there are cases where diverting the carriageways must be contemplated on a regular basis. It is especially the case in the vicinity of toll stations or still in mountainous zones exhibiting galleries that must be maintained and where it is preferable to close the traffic completely by diverting it to the opposite carriageway.
Thus, if the state of the art knows communication zone retention devices is that can be open or closed by a single person without any heavy equipment, the latter only relate to a few ten meter-wide passages that can be used for diverting traffic carriageways and/or that exhibit smaller retention capacities with respect to the permanent separators.
The purpose of the invention is therefore to remedy these shortcomings and to suggest a discontinuance device for a central reserve in a communication zone between carriageways that exhibits a same level retention capacity or, still, close of those of the upstream and downstream permanent separators over a width ranging from a few meters to several tens of meters and that can be handled quickly and without any heavy equipment by one operator.
The invention therefore relates to a discontinuance device for a central reserve fitted with a permanent separator for a communication zone between carriageways exhibiting a closing position ensuring continuity of the separation of the carriageways and opening positions, respectively traffic emergency and diversion opening positions, where the carriageways are connected, made of fabricated metal modules and comprising supports driven into the ground.
SUMMARY OF THE INVENTION
According to the invention, the device comprises:
at least one arm consisting of at least one arm module, whereas the said module has two lateral walls, whereby the said arm is mobile in rotation around a vertical axle forming a joint at one of its ends, whereas the said arm comprises at least one pivoting retractable foot containing castors intended for lifting and bringing the said arm into rotation in order to ensure easy opening for traffic diversion;
a locking module mobile in translation on the arm in order to provide an emergency opening.
The invention also relates to the characteristics thereunder, considered individually or according to all their technically possible combinations:
two connection modules are arranged between both ends of the device and both ends of the permanent separators, whereas the said connection modules are intended for ensuring continuity of the separation with both adjacent permanent separators;
each support is arranged in a sheath driven into the ground, whereas the said support is retractable in order to be disengaged from the ground and arranged in a spacer, whereas the said spacer is integral with the lateral walls of an arm module;
the arm and locking modules have a trapezoidal profile, the lateral walls of the said modules are closed and ground-resting plates are arranged laterally at the base of the said modules, in order to strengthen the retention capacities of the said modules;
the arm module is rigidified by at least two ribs provided along each lateral wall and by at least one internal reinforcing piece;
each lateral wall of the locking module comprises along its internal face at least two U-shaped profiles for strengthening, whereas each of the said profiles comprises at least two lateral guiding castors distributed along the said profiles and one removable castor is arranged at one end of the said module;
each arm module intended for receiving the locking module that would then move to cover the former, comprises at its upper face at least one pair of castors;
the spacer comprises a joint so that the removable support, once retracted from the ground, can be tilted horizontally in order to remain inside the gauge delineated by an arm module;
the axle forming the joint is a support driven into the ground made of a round metal tube and the tube is arranged in at least one spacer comprising an adapted circular passage, whereas the said spacer is integral with the lateral walls of an arm module;
the device comprises a retention means intended for limiting the rotary opening of the arm up to a pre-set position;
the assembly between a first arm module and a second module of the same arm is obtained by bolting or keying the corresponding end of the second module on an integral linking frame and protruding from the first module;
the assembly between a first arm module and a second module of the same arm is obtained by covering-overlapping and bolting or keying the corresponding ends of the said modules;
the assembly between two modules of the same arm is ensured by bolting or keying an add-on part overlapping and covering the corresponding ends of the said modules;
as the device is closed, the locking module is keyed on the modules of adjacent arms;
the connection module arranged between the end of the arm comprising the joint and the permanent separator exhibits two closed lateral walls and comprises at its upper part a joint-holding arm;
the arm module is approx. 0.8 m in height, 0.6 m in width at the base, whereas the base is extended laterally by two ground-resting plates, each 0.15 m in width, 0.27 m in width at the apex for a 3.5 m length.
stops are provided on the arm modules in order to limit the covering translation movements of the locking module;
the rising or descending movements of the retractable pivoting axle comprising castors are controlled by a screw-jack type means or similar;
in one arm, the rising and descending movements of the retractable pivoting foot comprising castors and the rising and descending movements of the support can be controlled by a single synchronised means;
the current length of the device is at least 32 m and it comprises two arms, each of the arms consisting of at least four arm modules.
Other advantages and characteristics of the invention will become apparent from reading the description of embodiment examples in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWING
On these drawings:
FIG. 1 represents a lateral view of a device in closed position.
FIG. 2 represents a device in several opening positions and seen from above.
FIG. 3 represents a lateral view of the device detailing the locking module in closed position.
FIG. 4 represents a lateral view of the device detailing the locking module in an opening position.
FIG. 5 represents a cross section of a locking module at a removable castor.
FIG. 6 represents a cross section of an arm at a locking arm according to a first embodiment.
FIG. 7 represents a cross section of an arm at a locking arm according to a second embodiment.
FIG. 8 represents a cross section of an arm module at a support.
FIG. 9 represents an upper view of a support and of the corresponding spacer.
FIG. 10 represents a cross section of an arm module at a retractable pivoting foot comprising castors.
FIG. 11 represents a cross section of a link between two arm modules according to a first embodiment.
FIG. 12 represents a lateral view of a linking zone between two arm modules according to a first embodiment.
FIG. 13 represents a lateral view of the connection zone between a permanent metal rail and the device according to the invention.
FIGS. 13 a , 13 b , 13 c represent cross sectional views of the device of FIG. 13 along the sections A—A, B—B and C—C respectively.
FIG. 14 represents an elevation view of the connection zone between a concrete wall and the device according to the invention.
FIG. 15 represents an example of synchronised mechanical control of the supports and of the removable feet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an embodiment of the device according to the invention. It comprises two articulated arms 2 , 2 ′ united by a locking module 10 . The device is intended to be placed in a communication zone between two carriageways on a central reserve. A first end of the device is extended by a permanent separator of concrete barrier type 3 and a second end of the device by a safety rail 3 ′ via two connection modules 50 and 50 ′. Each of the arms 2 and 2 ′ consists of four arm modules 20 , approx. 3.5 m in length, whereas an arm is then 14 meters in length. The arm modules 20 are united together at assembly zones 21 . Each arm module 20 exhibits on each of both its lateral faces, continuous and closed, at least two ribs 23 . The locking module 10 comprises two continuous plane lateral faces. Continuity means that the module is not open laterally, limiting the consequences in case of a collision with a motorbike. The width of the communication zone is then approx. 28 meters. Each arm 2 and 2 ′ is mobile on the horizontal plane around a pivoting axle forming a joint 33 and 33 ′ respectively. The joint 33 or 33 ′ is situated at the end of the arm 2 or 2 ′ adjacent to the corresponding connection module 50 , 50 ′. The ends of the arms 2 , 2 ′ opposite the joints 33 and 33 ′ are linked together via the locking means 10 . The pivoting axle forming a joint 33 or 33 ′ is driven into the ground substantially vertically so that the arms move into rotation horizontally over a horizontal communication zone. An arm module 20 comprises at least one support 30 or its equivalent in the form of the pivoting axle forming a joint 33 , 33 ′, which is driven into the ground. The modules forming the device consist essentially of galvanised steel sheets, reinforcing pieces, supporting spacers and are essentially hollow. The steel used exhibits at least the features of the steel S 235 JR according to French Standards NF EN 10 025 and sustains galvanisation according to French Standards NF A 35-503. Galvanisation will be obtained by quenching according to French Standards NF A 91-121.
FIG. 2 shows the device in open position according to three possibilities given for exemplification purposes.
In a first position, both arms are collinear to one another on the central reserve 5 and the locking module 10 is translated by overlapping one of the arms 2 in order to provide an emergency opening in the communication zone. For a locking module of approx. 6 meters in length, an approx. 4 meter long emergency opening is obtained. The supports 30 , in this position, are driven into the ground in their sheaths.
In the following opening configurations represented on the same FIG. 2, the arms have been moved into rotation around the joints 33 and 33 ′ in order to allow switching between double and quadruple carriageway traffic according to the opening angle. Concrete blocks 4 can be placed ahead of the end of the arm and parallel to the traffic axis. In a particular embodiment, a hooking means is provided between the corresponding end of the arm and the concrete block. To enable the arms to rotate, the supports 30 have been extracted from the ground where they were inserted inside their sheaths. Once the device has reached its open position, the supports can be reinserted in the ground inside sheaths which, normally, when the communication is not open, will be closed by a covering system leveling with the road so that they cannot be filled by any debris or cannot disturb the traffic. Such a removable covering system may also be foreseen for the sheaths situated on the central reserve. The sheaths will then be closed when diverting the traffic.
FIG. 3 is a view of the closed device according to FIG. 1 detailing more particularly the locking module 10 and the adjacent arm modules 20 . The locking module rests on both its ends on the corresponding ends of the said arm modules. The locking module and the arm modules are keyed together via the keys 15 . As the locking means can move by translation over the arm modules, stops are provided in order to limit the bottoming of the said locking module. A first series of stops 29 ′ is arranged on the arm module 20 at the end of the arm 2 ′, in order to stop the locking module 10 in closed position.
FIG. 4 represents the device in a first opening position, whereas a second series of stops 29 , blocking the locking module 10 in open position, is arranged on an arm module of the arm 2 . The locking module has been translated by covering the arm 2 . The keying means 15 have been removed and will be, preferably, stored in a receptacle provided in the device. However, when the opening must be kept, keying means 15 ′ could also be used to fix the locking module in this opening position. Rolling means, described below, are used for that purpose and enable single-operator control of the locking module without any heavy means. The translation of the locking module can be facilitated by a handle or a removable thrust arm.
FIG. 5 represents a cross section of a locking module 10 at the end comprising a removable castor 13 . The end comprising the said castor 13 is opposite the arm receiving in translation the said locking module so that the opening of the said translation and covering locking element can be maximum, whereas the arm modules 20 contain internally reinforcing pieces 26 , supports 30 and other elements capable of opposing the internal passage of the said removable castor 13 . In a closed device, the removable castor 13 is retracted and does not rest on the ground. When opening the device, the removable castor 13 is lowered or tilted to touch the ground. Lowering or tilting the castor can be obtained by any means known to the man of the art, i.e. a screw-type system, mechanical jack, pneumatic, hydraulic or electric jack. The castor will be preferably fixed and oriented to be able to roll into the locking module. Still, it is also contemplated that the castor should be mounted to pivot with respect to its supporting axle. This configuration is useful when the castor is still resting on the ground during the rotation of the corresponding arm for opening. The locking module 10 exhibits in its cross-section a substantially trapezoid and symmetrical shape, with a wide base, on the ground side, and an upper, opposite, narrow apex. The lateral sides connecting the ends of the base and of the apex as well as the upper wall forming the apex are substantially plane and continuous. The base of the module 10 is open. Two ground resting plates 16 are provided at the base of the module 10 , laterally, along each side. These ground-resting plates are intended for improving the stability and the retention capacity of the device in case of shock, whereas the wheel(s) of the vehicle are pressing the resting plate to the ground. The internal faces of both lateral sides of the locking module comprise U-shaped metal profiles 11 designed for reinforcing the stiffness of the module. These profiles 11 are preferably welded and are each arranged at a height corresponding to the ribs 23 , described below, of the arm modules 20 so that the translation of the module 10 on the arm 2 can take place undisturbed. Lateral guiding castors 12 are arranged along the said profiles 11 . The lateral guiding castors 12 are intended for circulating in the ribs 23 provided on the lateral walls of the arm modules 20 . The locking module is preferably realised from a single metal plate that is to folded. However, it is also contemplated to build the locking module by the reunion of two, or several, metal plates by welding and/or bolting.
FIGS. 6 and 7 enable visualising thanks to a cross section of an arm at a locking module, two embodiments of the system enabling the rolling of the locking module 10 on the arm modules 20 of the arm 2 at the upper part of the device. In the first embodiment, FIG. 6, at least one pair of upper guiding castors 14 is fastened to the apex wall of the locking module 10 . Raceways 24 are available on the lateral parts of the upper face of the apex walls of the arm modules 20 . The cross section goes through an internal reinforcing piece 26 of an arm module 20 . The base of the internal reinforcing piece 26 could come down to the level of the ground resting plates 28 . In this mode, only the locking means 10 comprises lateral 12 and upper 14 guiding castors, enabling covering translation of the said module 10 on the corresponding arm 2 . This figure represents the keying means 15 , however they may be arranged at other height levels and along the modules. In the second embodiment, FIG. 7, at least one pair of castors 27 is fixed towards the apex of the arm 2 and raceways 17 are available on the lower face of the apex wall of the locking module 10 . The cross section goes through an internal reinforcing piece 26 ′ carrying the pair of castors 27 . In this mode, castors are also provided on the locking module and on the arm simultaneously.
The respective dimensions of the locking means 10 and of the arm modules 20 are suited so that the translation of the locking module 10 on the arm 2 takes place unimpeded. It can be noted on FIGS. 6 and 7 that the arm module 20 has ground-resting plates 28 , at its base and laterally, which fulfill the same function as those, 16 , of the locking module 10 . However, the shape of the resting plates 16 of the locking module 10 enables their translation on those 28 of the arm module 20 . It will also be noted that the centre portion of the apex of the arm modules is open, thereby providing access to the internal elements and in particular to the supports 30 , to the castor-operated retractable pivoting axles 40 and allowing the passage of the removable castor 13 of the locking module 10 . An arm module 20 has approximately the following dimensions: 0.8 m in height, 0.6 m in width at the base and 0.9 m integrating both ground resting plate 28 , whereas each resting plate 16 or 28 is approximately 0.15 m in width. An arm module 20 is approximately 3.5 m in length. The locking module 10 is approximately 6 meters in length. The thickness of the metal plates is preferably 3 mm except for the locking module where a 4 mm thickness is preferred.
FIG. 8 is a cross section of an arm module 20 at a support 30 . In the device in idle position, closed position, the support is driven into the ground, inserted in a sheath 31 . The sheath is driven in the ground. The arm module 20 has an external gauge whose trapezoidal shape is substantially equivalent to that of the locking module 10 . The lateral walls of the arm module 20 exhibit however longitudinal ribs 23 intended for improving the stiffness of the device. In this embodiment, two ribs 23 per lateral wall are foreseen. Ground-resting plates 28 are arranged laterally on either side along a module in order to improve the stability and the retention capacity of the module in case of shock. The module will be preferably realised by the joining of two folded metal plates. The support 30 goes through a spacer 32 , whereas the said spacer is fastened to both lateral walls of the arm module 20 . In this particular embodiment, the spacer 32 consists of three elements bolted together. However, in other embodiments, the spacer can be realised as a single block and/or the elements can be welded together. As the support 30 is driven into the ground in a sheath 31 , its length will be preferably such that the support will be comprised within the internal gauge of the arm module 20 . In other embodiments, some of these supports may be longer and possibly protrude from the gauge of the standard module. Still, the end supports 30 of the arm 2 should not prevent covering translation of the locking means on the end of the said arm regardless whether they have been driven into the ground into the sheaths or they have been extracted. In order to maintain the support 30 with respect to the spacer 32 , a removable blocking round 34 is provided either above the spacer in order to prevent the support 30 from coming down too deep inside the sheath 31 or through the spacer 32 and the support 30 in order to block any relative movement between both these parts. Two corresponding orifices are provided, in the support and, possible matching, in the spacer, in order to insert the said blocking round 34 . Similarly, an equivalent blocking means can be foreseen between the sheath 31 and the support 30 in order to block any relative movement between both items when the support has been driven into the ground. This latter blocking means is placed below ground level so that the sheath does not protrude and it will be preferably masked by a cowling once the supports have been removed, whereas the device is open, so as not to disturb the traffic. The blocking rounds can be removed individually but it is also foreseen that they could be disengaged simultaneously from all the supports. In the latter case, all the rounds will be connected to a cable or to a rod assembly, and one or several return springs bringing the rounds back to engagement and blocking position will be provided. The operator will simply have to pull on the cable or on the rod assembly to disengage the rounds. A round's guide integral with the spacer will maintain the round in axial position during these engaging and disengaging movements. Transmission means will be provided between the bales or the rod assembly of the different modules assembled together.
To enable the opening of the communication zone, the supports 30 will be extracted from their sheaths 31 in order to disengage the former completely from the ground. The supports 30 could then be either removed completely from the device or left in place in the device while providing as previously a blocking round 34 ′ arranged so that the support is immobilised in a position where it is not engaged any longer in the ground. In this latter case, the support protrudes from the upper part of the gauge of the standard module. This is a shortcoming at the end of the arm 2 where the locking module 10 must be translated by covering. Also, in this zone, the supports 30 should be removed preferably from the device. It is also contemplated in another embodiment that the spacer comprises a joint that enables horizontal tilting of the support once extracted from its sheath 31 so that the said support is totally comprised within the gauge of the arm module 20 and does not interfere with the opening of the locking module 10 . The extraction from the sheath 31 of the support 30 can be performed by any means, manually, by a gear system or mechanical jacks and/or hydraulic and/or pneumatic and/or electrical jacks.
FIG. 9 represents the spacer 32 of FIG. 8 seen from above where the three elements are bolted together. The bolting orifices are preferably oblong to compensate for the clearances. The support 30 consists preferably of a metal tube with 101.6-mm diameter and 3.6 mm thickness, whereas the sheath is then 114.3 mm in diameter and 3.6 mm in thickness. The portion driven into the ground as well as the length of the sheath is approximately 700 mm, but this value will be adjusted in relation to the terrain. The diameter of the passage allowing the support to go through the spacer is 114.3 mm. However, it is also contemplated to use other forms of supports, for example U-shaped or square or rectangular. The pivot axle for rotation forming the joint 33 or 33 ′ is essentially constructed according to the principles described for the supports. However, the axle selected will be a metal tube that enables rotation of the spacer, whereas the said tube is preferably fixed in place in the ground. Still, in other embodiments, whereby the pivot axle can be maintained at its upper part by a joint holding arm 38 or 38 ′ of the connection module 50 or 50 ′ as explained later, the tube can be put into the ground, in a sheath. Besides, more than just one spacer at the joint 33 , 33 ′ can be provided in order to strengthen the former. If both spacers are used for the joint, the first one will be placed facing the upper part of the arm module and the second facing the lower part.
FIG. 10 represents a cross section of an arm module 20 at a retractable pivoting foot fitted with castors 40 . Pivoting the foot enables, when the castors are on the ground, rolling in all possible directions. As the device is closed, the feet are removed and do not rest on the ground, whereby the modules then rest via supporting plates 28 on the ground. To open the device, the feet are actuated by any means that enables lowering them onto the ground via a gear system, a screw-type jack, a mechanical, pneumatic, hydraulic or electrical jack so that they rest on the ground and lift the module and hence the arm. As the arm is raised, the operator can easily open the device for diverting the traffic by pushing and pivoting the arms 2 , 2 ′ around their joints 33 , 33 ′. Once the requested position of the arm has been achieved, the retractable pivoting feet with castors are retracted so that the modules rest again on the ground. The supports 30 may then be re-implanted in the ground and the ends of the arms may be fixed to concrete blocks 4 . Preferably, the movements of all the castor feet 40 of the modules 20 of an arm will be synchronised via a common mechanical transmission such as transmission axle and gear, pneumatic, hydraulic or electrical jack. It is also contemplated that the retraction and/or positioning movement of the supports and the lowering and/or raising movement of the castor feet 40 should be synchronous. FIG. 15 gives an example of such a purely mechanical device where an incomplete rack only engages into the castor foot 40 when the support is disengaged sufficiently from its sheath. The other mobilisation modes will use actuating members controlled by contractors, valves or other equivalent items, operated in relation to the positioning of the supports 30 and the castor feet 40 . In an arm module 20 comprising at the same time at least one support and at least one castor foot 40 , the movements of both these elements are therefore synchronous, whereas a transmission 36 comprises at both its ends a coupling member 37 for joining with the matching coupling member of the transmission of the adjacent module or with a crank or any other device enabling setting the transmission in motion. It is however foreseen that the transmission could always be set in motion by a meshing and/or intermediate system. Similarly, synchronism can be provided with an arm 2 , 2 ′ consisting of any type of different arm modules 20 .
Several embodiments are considered for interconnecting two adjacent arm modules 20 at the assembly zone 21 . FIG. 11 represents a cross section of the junction between two arm modules 20 according to a first embodiment. In this embodiment, the end of a first module 20 comprises internally a metal linking frame 35 , whereas the said frame is welded to the said module and protrudes from the said. The corresponding end of the second module 20 comprises bolting orifices 25 on its lateral walls. These orifices are oblong in order to compensate for the clearances and the expansion of the metal. The said end of the second module is positioned on the protruding section of the linking frame of the first module in order to align the bolting orifices of these two elements. In addition to its mission as a linking element, the linking frame 35 plays an internally strengthening and realisation part, thus the lateral walls of the modules lie behind one another. It is also foreseen that the linking frame comprises means for allowing a support to go through, whereas the said frame fulfills then all the functions of a spacer and of a simple linking frame.
In other embodiments of the linking system, it is contemplated that the link between two arm modules consists in covering lateral walls according to two possibilities. In the first one, by partial overlapping of the ends of the modules, the end walls of one of the modules are offset, i.e. either recessed or protruding with respect to the general plane of the walls. Ends of both types are then defined, on the general plane and outside the general plane, and can be coupled. In the second possibility, overlapping add-on plates will be bolted to the walls of both ends of both adjacent modules as external or bilateral fishplates.
FIG. 13 represents the connection zone between a permanent separator such as a safety rail 3 ′ and an arm 2 of the device. A connection module 50 ′ is arranged between the end of the rail 3 ′ and the end of the arm 2 ′ comprising the joint 33 ′. The connection module 50 ′ exhibits a beveled end that can be inserted between both metal profiles of the rail 3 , as visible on FIG. 13 c . In this particular embodiment, a joint holding arm 38 ′ is fixed to the upper section of the end of the connection module 50 ′, on the arm side 2 ′. The holding arm 38 ′ enables fastening the upper part, protruding from the arm module 20 , of the pivoting axle forming a joint 33 ′. In other embodiments, and in particular when the pivoting axle forming a joint is anchored to the ground, the holding arm 38 ′ can be omitted. The connection module 50 ′ will be preferably fixed to the end of the rail 3 ′ and will comprise preferably internal reinforcing pieces and one or several supports driven into the ground that will be preferably anchored to the ground. The approximate length of this connection module is 3.50 meters. The lateral walls of the arm module 20 comprising the joint 33 ′ will be preferably covered towards the joint so that the ribs 23 are masked, whereas the lateral profile is then similar to that of the connection module 50 ′, FIGS. 13 a and 13 b.
FIG. 14 represents an upper view of the connection zone between a permanent separator such as a concrete wall 3 and the articulated end of an arm 2 . The connection arm 50 comprises a joint-holding arm 38 . The arm 38 is fixed to the upper section of the pivoting axle forming a joint 33 . The approximate length of this connection module is 1.50 meters in order to be able to switch from the profile of the concrete permanent separator to the profile of the arm modules. The module 50 will be preferably bolted to the end of the permanent separator 3 .
On FIGS. 6, 7 , 8 , 9 , the cross section goes through metal reinforcing pieces 26 and 26 ′ or spacers 32 inside the arm modules. These elements are intended for interconnecting the lateral walls and for reinforcing the structure of the arm modules 20 . The respective numbers of internal reinforcing pieces 26 , 26 ′, spacers 32 , inside the arm modules 20 or the connection modules 50 , 50 ′ will depend of the retention capacity required for the device. For a 3.5 meter long arm module comprising a module-linking frame 35 , one support and one internal reinforcing piece are provided preferably. If higher retention capacity is required, at least two supports and two reinforcing pieces will be provided. However, all the possible combinations of numbers of these elements are contemplated, whereas the purpose is to obtain sufficient retention capacity at the best price. The modules 10 , 20 , 50 , 50 ′ are preferably symmetrical with respect to a longitudinal vertical middle plane.
Tests performed with a two-arm device with total length of 32 meters, have shown that the opening for diverting the traffic could be carried out by a single operator without any particular heavy equipment, especially lifting equipment, in less than 15 minutes. The operator can push each arm over a road exhibiting an axle camber in the order of 4%, no load heavier than 40 kg needs to be carried, in spite of an arm weight greater than 1500 kg. During this process, the operator is protected by the device.
The reference signs inserted after the characteristics mentioned in the claims solely aim at facilitating the understanding of the latter and do not limit their extent in any way. Moreover, the examples of embodiments are only given for informative and illustrative purposes and all the possible combinations of these examples as well as the variations are part of the description. In particular, a device comprising one arm only is contemplated. It comprises a first connection module on the upstream permanent separator, a joint-operated arm, a locking module according to the previous description and a second connection module that can accommodate the end of the locking means and be keyed to the same. The said second connection module can be coupled to the downstream permanent separator. Moreover, the operation of the device may be partially or totally controlled remotely, whereby electrical, pneumatic, hydraulic actuating members and detectors would ensure and monitor the movements of the different mobile elements. It is also contemplated that the arm modules 20 are partially or totally standardised and that they can be used indifferently along a given arm. In such a case, the embodiment presented on FIG. 6 will be preferred, the stops 29 and 29 ′ will be removable to be placed solely to suit the requirements and the linking mode between the modules 20 will be chosen accordingly, either the module 20 does not comprise any linking frame or a covering system is selected. The control of the movements of the supports 30 and of the retractable pivoting feet fitted with castors 40 can be transmitted, as indicated, commonly and synchronously or not. The same goes for the blocking rounds 34 . Besides, this(these) transmission(s) can take place commonly along the arm for all the mobile members. For example, a longitudinal transmission axle could be terminated at each end of a module with a coupling device that enables, when the arm modules are joined, to couple and to transmit the control from one end of the arm to the other and to the following arm. Finally, it is foreseen that a means enabling to limit the bottoming of the arm when rotating, a retaining means, should be included in the device. This means could be a brake acting on the castors of one or several retractable pivoting axles 40 , a cable linked to the arm and anchored to the ground on the central reserve, a stop anchored to the ground close to the joint according to two positions or a simple wedge resting on the ground at the requested location for the arm in opening position for diverting the traffic.
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A discontinuance device for a central reserve is fitted with a permanent separator for a communication zone between carriageways, provides a closing position to ensure continuity of the separation of the carriageways and opening positions, for traffic emergency and diversion opening positions where the carriageways are connected. The device is made of fabricated metal modules comprising supports driven into the ground. The device includes at least one arm having at least one arm module. The module has two lateral walls. The arm is mobile in rotation around a vertical axle forming a joint at one end thereof. The arm includes at least one pivoting retractable foot containing castors to lift and bring the arm into rotation, and to ensure an easy opening for traffic diversion. A transitionally mobile locking module on the arm provides an emergency opening.
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BACKGROUND OF THE INVENTION
This invention relates to electrostatographic imaging systems and more specifically to improved carrier compositions useful in the development of electrophotographic images.
It is well known to form and develop images on the surface of photoconductive materials by electrostatic means, one of the more basic systems being described in C. F. Carlson U.S. Pat. No. 2,297,691. This process is also described in other U.S. patents, including for example, U.S. Pat. No. 2,277,013, U.S. Pat. No. 2,357,809, and U.S. Pat. No. 2,551,582, U.S. Pat. No. 3,220,324 and U.S. Pat. No. 3,220,833. The processes described in these patents generally involve the forming of a latent electrostatic charge image on an insulating electrophotographic element whereby the latent image is made visible by a development step wherein the charged surface of the photoconductive element is brought into contact with a suitable developer mix. As described in U.S. Pat. No. 2,297,691, for example, the resulting electrostatic latent image is developed by depositing on the image a finely-divided electroscopic material referred to in the art as toner. This toner is generally attracted to the areas of the layer which retain a charge, thereby forming a toner image corresponding to the electrostatic latent image and subsequently the toner image can be transferred to a support surface such as paper. This transferred image can then be permanently fixed to the support surface by using a variety of techniques including heat; however, other suitable fixing methods such as solvent or overcoating treatment may be used.
Numerous methods are known for applying the electroscopic particles to the electrostatic latent image including cascade development, touchdown and magnetic brush belt. In cascade development, as described in U.S. Pat. No. 2,618,552, a developer material comprising relatively large carrier particles having finely-divided toner particles electrostatically clinging to the surface of the carrier particles is conveyed to and rolled or cascaded across the electrostatic latent image bearing surface. The composition of the toner particles is selected in order to have a triboelectric polarity opposite to that of the carrier particles. Thus, as the mixture cascades or rolls across the image bearing surface, the toner particles are electrostatically deposited and secured to the charged portion of the latent image and are not deposited on the uncharged or background portions of the image. Carrier particles and unused toner particles can then be recycled. This process is fully described by E. N. Wise in U.S. Pat. No. 2,618,552.
In the touchdown process as described in U.S. Pat. Nos. 2,895,847 and 3,245,823, a developer material is carried to a latent image bearing surface by a support layer, such as a web or sheet and is deposited thereon in conformity with the image.
In magnetic brush development, a developer material comprising toner and magnetic carrier particles is carried by a magnet whereby the magnetic field of the magnet causes alignment of the magnetic carriers into engagement with an electrostatic latent image-bearing surface, causing the toner particles to be attracted from the developer to the electrostatic latent image by electrostatic attraction. This process is described more fully in U.S. Pat. No. 2,874,063.
Carrier materials used in the development of electrostatographic images are described in many patents including U.S. Pat. No. 3,590,000, the nature of the material being used being dependent on numerous factors such as the type of development used, the quality of the development desired, the type of photoconductor employed and other factors including durability. Generally, the materials used as carrier surfaces or carrier particles, or coatings thereon, should have a triboelectric value commensurate with the triboelectric value of the toner, in order to enable electrostatic adhesion of the toner to the carrier. Also, the triboelectric charging properties of the carrier should be relatively uniform in order to allow uniform pickup and subsequent deposition of toner. Further, carrier coatings should preferably have a certain hardness primarily for durability purposes but yet made of materials that will not scratch the plate or drum surface upon which the electrostatic image is initially placed. Carriers should also be selected that are not brittle so as to cause flaking of the surface or particle breakup under the forces exerted on the carrier during recycle as such will cause undesirable effects and could, for example, be transferred to the copy surface thereby reducing the quality of the final image. In addition, there are several types of carrier materials which, although having the proper triboelectric properties, are of limited use in a development system because of the limitations they possess, as described above, which result in undesirable results.
Some recent efforts have focused on the carrier particles, and more specifically the coating of these particles in order to obtain a better development system, particularly a developer that can be recycled and does not cause injury to the photoconductor. However, many of the coatings utilized deteriorate rapidly, particularly when used in a continuous process, and sometimes the entire coating separates from the carrier core in the form of chips or flakes which may be caused by poorly adhering coating material that fails upon impact and abrasive contact with machine parts and other carrier particles. Generally, such coated carrier particles cannot be reclaimed and reused, and further, poor print quality results when damaged carriers are not replaced. Also to be taken into consideration is the triboelectric and flow characteristics of coated carriers since such properties may be adversely affected when relative humidity is high. Thus, for example, the triboelectric values of some carrier coatings fluctuate when changes in relative humidity occur and such carriers are not desirable for use in electrostatic systems since they adversely affect the quality of the resulting image.
The importance of carrier coatings takes on increased emphasis in different development techniques. Generally, in order to develop a latent image comprised of negative electrostatic charges, an electroscopic powder and carrier combination is selected in which the powder is triboelectrically positive relative to the granular carrier. To develop a latent image comprised of positive electrostatic charges, such as when employing a selenium photoreceptor, an electroscopic powder and carrier is selected in which the powder is triboelectrically negative relative to the carrier. Thus, where the latent image is formed of negative electrostatic charges, such as when employing organic electrophotosensitive materials as the photoreceptor, it is desirable to develop the latent image with a positively charged electroscopic powder and a negatively charged carrier material.
PRIOR ART
A recent development in the art of providing coated carrier particles for electrostatographic development is disclosed by R. W. Madrid et al in U.S. Pat. No. 3,850,676. It is therein indicated that development may be obtained in an imaging system employing a developer mixture wherein the carrier particles are coated with a thin layer of a solid polyphenylene oxide resin or a blend of a polyphenylene oxide resin and a thermoplastic or thermosetting resin. The carrier particles are reported to possess high resistance to toner impaction and coating abrasion resistance. However, the triboelectric properties of these carrier materials are unsuitable for use in developing electrostatic latent images when the photoreceptor is charged to a negative polarity. Another effort in the art of providing coated carrier particles for electrostatographic development is reported by C. A. Queener et al in U.S. Pat. No. 3,778,262. The coating composition therein is formed of a mixture of a fluoropolymer and epoxy. After application to carrier cores, the coating composition is cured by heating the carrier particles at a temperature below 700° F. for about 15 minuites to ensure adherence of the coating to the cores and provide particles which have an electronegative characteristic with respect to toner particles. However, it has been found that such carrier particles possess coatings which are usually brittle and have poor adhesion properties with concomitant tendencies to separate, flake, or break away from the carrier cores. Consequently, the triboelectric charging properties of such carrier materials become non-uniform resulting in poor quality development and the useful life of the developer mixture is minimized. Thus, there is a continuing need for improved coated carrier particles for use in an electrostatographic imaging system.
SUMMARY OF THE INVENTION
It is therefore, an object of this invention to provide developer materials which overcome the above-noted deficiencies.
It is another object of this invention to provide carrier materials which have excellent adherence to carrier substrates.
It is a further object of this invention to provide carrier coatings which are more resistant to cracking, chipping, flaking, and have high tensile and compressive strength.
It is a further object of this invention to provide coated carrier materials having improved triboelectric characteristics, greatly increased life, better flowability properties, and which materials can be reclaimed if desired.
Furthermore, it is an object of this invention to provide improved developer materials, especially improved coated carrier materials which may be used in an electrostatographic development environment where the photoreceptor is charged to a negative polarity.
It is yet another object of this invention to provide improved coated carrier materials having physical and chemical properties superior to those of known developer materials.
The above objects and others are accomplished, generally speaking, by providing a carrier for electrostatographic developer mixtures comprising finely-divided toner particles electrostatically clinging to the surface of carrier particles wherein said carrier particles comprise a core having an outer coating thereon comprising a polyblend of a first polymer possessing negative triboelectric charging characteristics with respect to toner particles, and a second polymer which possesses strong adhesive properties with respect to said core.
In general, during application of the polymer blends of this invention to carrier cores and removal of the solvent such as by evaporation, separation of the polymers in the polyblend occurs so that the second polymer migrates to the surface of the carrier cores while the first polymer migrates to form the outer surface of the carrier core coating. In this manner, the polyblend coating materials of this invention provide carrier particles having improved properties and which can be used in an electrostatographic development system, especially where development of a negatively charged photoreceptor is desired. In accordance with this invention, it has been found that the carrier coating materials of this invention provide electrostatographic coated carrier materials which possess longer useful lives and which are capable of generating negative triboelectric charging properties. By comparison, copolymers of the same material compositions applied to carrier cores in identical manner provide coatings having poor adhesion, and in some cases, coatings which are brittle.
As the first polymer possessing satisfactory negative triboelectric charging characteristics with respect to toner particles may be employed soluble fluoropolymers such as vinylidene fluoride, for example, Kynar 201 available from Pennwalt Corporation, Philadelphia, Pa.; terpolymers comprising vinylidene fluoride, tetrafluoroethylene, and vinyl butyrate such as Fluoropolymer "B" available from E. I. duPont Co., Wilmington, Del.; and copolymers and homopolymers of fluorinated acrylates and methacrylates such as poly-hexafluoro-isopropyl methacrylate.
As the second polymer possessing strong adhesive properties with respect to the carrier core may be employed soluble acrylics such as styrene and alkyl acrylates and methacrylates, for example, copolymers of styrene and methyl methacrylate, terpolymers of styrene, methyl methacrylate and an organosilane; methyl methacrylate and methacrylic acid copolymers, styrene and methacrylic acid copolymers; polymethacrylonitrile and copolymers thereof; acrylonitrile copolymers such as those containing vinylidene chloride; copolymers containing methacrylic acid and salts thereof; polysulfones; polycarbonates; polyesters such as polycaprolactone, polyhexamethylene terephalate; polyamides such as Trogamid T (poly 2,2,4-trimethylhexamethylene terephthalamide available from Dynamit Nobel of America); and other polyamides such as Amidel (a transparent Nylon® available from Union Carbide Corp., New York, N.Y.).
Any suitable combination of the aforementioned polymers may be employed as the polyblend to form the carrier coatings of this invention. Typical polyblends include hexafluoroisopropyl methacrylate and dimethylaminoethyl methacrylate; a terpolymer comprising about 70 molar percent of vinylidene fluoride, about 20 molar percent of tetrafluoroethylene, and about 10 molar percent of vinyl butyrate (such as "Fluoropolymer B", available from E. I. duPont Co., Wilmington, Del.) with styrene-methyl methacrylate copolymers; "Fluoropolymer B" with vinylidene chloride-acrylonitrile copolymers; fluoropolymers blended with amorphous, highly wax-compatible vinyl polymers such as Elvax ionomers available from E. I. duPont Co., Wilmington, Del., cellulose nitrate, polysulfones, polymethacrylonitrile, or copolymers of polymethacrylonitrile; mixtures of polycaprolactone or polyhexamethylene terephthalate with polyvinylidene fluoride, polyvinyl chloride, polyvinyl chloride-vinylidene chloride copolymers; blends of nitrocellulose, styrene-acrylonitrile copolymers, polyethylene, acrylonitrile-butadiene-styrene terpolymers, vinyl-chloride-acrylonitrile copolymers, and a fluoropolymer. Polycaprolactone has been found to be an especially effective dispersant for a variety of pigments in thermoplastic systems, and in particular, for dispersing carbon black in such systems.
Especially preferred polyblends include mixtures of a fluoropolymer and an acrylic copolymer or homopolymer containing polar groups such as carboxylic acid, amine or alcohol because the resulting carrier coatings have been found to possess strong adhesive properties and to provide the desired negative triboelectric charging characteristics. After application to carrier cores, these polyblends have been found to provide the combined properties of strong adhesion to carrier cores such as metal cores, mechanical toughness, and lower surface energies. Thus, by this invention, the major problem of poor carrier core adhesion associated with low surface energy carrier coatings has been overcome.
Any suitable ratio of first polymer may be employed with respect to the ratio of the second polymer in the polyblends for the electrostatographic carrier coatings of this invention. Typical ratios of the first polymer to the second polymer include from about 5 parts to about 95 parts by weight of the first polymer to from about 95 to about 5 parts by weight of the second polymer. However, it is preferred to employ from about 20 parts to about 80 parts of the first polymer to from about 80 parts to about 20 parts of the second polymer, all parts given being by weight, because coated carrier materials possessing more satisfactory physical and electrostatographic properties are obtained. In addition, it is preferred to employ as the first polymer a halogenated polymer such as a fluoropolymer because it migrates to the carrier coating surface and the coated carrier particles have low surface energies. Further, it is preferred to employ as the second polymer an acrylic polymer because the coating has good mechanical properties and adhesion to carrier cores, especially steel and ferrite cores.
It is to be noted that the polymer blends of this invention will possess various degrees of compatibility. On a scientific basis, a truly compatible polymer blend is one that displays a single glass transition intermediate between the glass transitions of the respective components. However, from a practical viewpoint, compatible polymer blends herein are those that can be readily prepared and display selected polymer properties equivalent or superior to the respective components. For illustration, the blending of 10 to 50 percent of polycaprolactone with polyethylene, polyvinyl chloride, vinyl chloride-vinylidene chloride, nitrocellulose, and styrene-acrylonitrile would be considered to result in compatible polyblends since the added polymer is readily dispersed in the host polymer matrix with no obvious sweat-out or deterioration in physical properties. Further two extreme cores can be distinguished. That is, where the polyblend results in complete phase separation, and where there is no phase separation. Practical polyblends of this invention are those where compatibility of the polyblend is intermediate between these extremes. It has been found that with a high degree of separation, the resulting carrier coating will generate triboelectric charging properties characteristic of the low surface energy polymer. Where the polyblend has a high degree of compatibility, the triboelectric charging properties of the carrier coating will be characteristic of the mixture. However, in all cases the advantage of improved carrier coating adhesion is obtained.
Any suitable polyblend coating weight or thickness may be employed to coat the carrier cores. However, a coating having a thickness at least sufficient to form a substantially continuous film is preferred because the carrier coating will then possess sufficient thickness to resist abrasion and minimize pinholes which may adversely affect the triboelectric properties of the coated carrier particles, and also in order that the desired triboelectric effect to the carrier is obtained and also to maintain a sufficient negative charge on the carrier, the toner being charged positively in such an embodiment so as to allow development of negatively charged images to occur. Generally, for cascade and magnetic brush development, the polyblend carrier coating may comprise from about 0.05 microns to about 3.0 microns in thickness on the carrier particle. Preferably, the coating should comprise from about 0.2 microns to about 0.7 microns in thickness on the carrier particle because maximum coating durability, toner impaction resistance, and copy quality are achieved. To achieve further variation in the properties of the final coated product, other additives such as plasticizers, reactive or non-reactive resins, dyes, pigments, conductive fillers such as carbon black, wetting agents and mixtures thereof may be mixed with the polyblend. In addition, where the carrier core is a conductive material, it is possible to provide carrier materials having conductive properties by providing the carrier core with a discontinuous or partial coating of the polyblends of this invention.
Any suitable well-known coated or uncoated carrier material may be employed as the core or substrate for the carriers of this invention. Typical carrier core materials include methyl methacrylate, glass, silicon dioxide, flintshot, ferromagnetic materials such as iron, steel, ferrite, nickel, and mixtures thereof. An ultimate coated carrier particle having an average diameter between about 30 microns to about 1,000 microns is preferred because the carrier particle then possesses sufficient density and inertia to avoid adherence to the electrostatic images during the development process. Adherence of carrier beads to an electrostatographic drum is undesirable because of the formation of deep scratches on the drum surface during the image transfer and drum cleaning steps, particularly where cleaning is accomplished by a web cleaner such as the web disclosed by W. P. Graff, Jr., et al. in U.S. Pat. No. 3,186,838.
Any suitable finely-divided toner material may be employed with the coated carriers of this invention. Typical toner materials include gum copal, gum sandarac, rosin, cumarone-indene resin, asphaltum, gilsonite, phenolformaldehyde resins, rosin modified phenolformaldehyde resins, methacrylic resins, polystyrene resins, epoxy resins, polyester resins, polyethylene resins, vinyl chloride resins, and copolymers or mixtures thereof. The particular toner material to be employed obviously depends upon the separation of the toner particles from the coated carrier beads in the triboelectric series. Among the patents describing electroscopic toner compositions are U.S. Pat. No. 2,659,670 to Copley; U.S. Pat. No. 2,753,308 to Landrigan; U.S. Pat. No. 3,070,342 to Insalaco; U.S. Pat. No. 25,136 to Carlson and U.S. Pat. No. 2,788,288 to Rheinfrank et al. These toners generally have an average particle diameter between about 5 and 30 microns.
Any suitable pigment or dye may be employed as the colorant for the toner particles. Toner colorants are well known and include, for example, carbon black, nigrosine dye, aniline blue, Calco Oil Blue, chrome yellow, ultramarine blue, Quinoline Yellow, methylene blue chloride, Monastral Blue, Malachite Green Oxalate, lampblack, Rose Bengal, Monastral Red, Sudan Black BN, and mixtures thereof. The pigment or dye should be present in the toner in a sufficient quantity to render it highly colored so that it will form a clearly visible image on a recording member.
Any suitable conventional toner concentration may be employed with the coated carriers of this invention. Typical toner concentrations include about 1 part toner with about 10 to 200 parts by weight of carrier.
Any suitable well-known electrophotosensitive material may be employed as the photoreceptor with the coated carriers of this invention. Well-known photoconductive materials include vitreous selenium, organic or inorganic photoconductors embedded in a non-photoconductive matrix, organic or inorganic photoconductors embedded in a photoconductive matrix, or the like. Representative patents in which photoconductive materials are disclosed include U.S. Pat. No. 2,803,542 to Ullrich, U.S. Pat. No. 2,970,906 to Bixby, U.S. Pat. No. 3,121,006 to Middleton, U.S. Pat. No. 3,121,007 to Middleton, and U.S. Pat. No. 3,151,982 to Corrsin.
Any suitable method may be employed to apply the polyblend coating materials to this invention to electrostatographic carrier cores. Typical methods include mixing, dipping, or spraying carrier cores with a solution or dispersion of the coating materials employing a vibratub or fluidized bed.
In the following examples, the relative triboelectric values generated by contact of carrier beads with toner particles are measured by means of a Faraday Cage. This device comprises a stainless steel cylinder having a diameter of about 1 inch and a length of about 1 inch. A screen is positioned at each end of the cylinder; the screen openings are of such a size as to permit the toner particles to pass through the openings but prevent the carrier particles from making such passage. The Faraday Cage is weighed, charged with about 0.5 grams of the carrier and toner mixture, reweighed, and connected to the input of a coulomb meter. Dry compressed air is then blown through the cylinder to drive all the toner from the carrier. As the electrostatically charged toner leaves the Faraday Cage, the oppositely charged carrier beads cause an equal amount of electronic charge to flow from the Cage, through the coulomb meter, to ground. The coulomb meter measures this charge which is then taken to be the charge on the toner which was removed. Next, the cylinder is reweighed to determine the weight of the toner removed. The resulting data is used to calculate the toner concentration and the average charge to mass ratio of the toner. Since the triboelectric measurements are relative, the measurements should, for comparative purposes, be conducted under substantially identical conditions. Obviously, other suitable toners may be substituted for the toner composition used in the examples.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples, other than the control example, further define, describe and compare preferred methods of utilizing the carrier materials of the present invention in electrostatographic applications. Parts and percentages are by weight unless otherwise indicated.
EXAMPLE I
A control developer mixture is prepared by applying a coating solution containing about 10 percent solids comprising about 100 parts of a terpolymer comprising about 70 molar percent of vinylidene fluoride, about 20 molar percent of tetrafluoroethylene, and about 10 molar percent of vinyl butyrate (Fluoropolymer B, available from E. I. duPont Co., Wilmington, Del.) dissolved in methyl ethyl ketone to steel carrier particles having an average particle diameter of about 250 microns. The carrier cores and the coating solution are simultaneously heated and suspended in a water-jacketed vibratub coating apparatus (available from Vibraslide, Inc., Binghamton, N.Y.). The coating solution is applied to provide about 0.8 percent by weight of the coating material based on the weight of the coated cores. After removal of the solvent, the coated cores are post-treated by heating in a vacuum oven at about 80° C. for about 1 hour and then mixed with a toner material comprising a styrene-n-butyl methacrylate copolymer, carbon black, and about 0.25 percent by weight based on the weight of toner material of tetraethylammonium bromide wherein the toner material has an average particle size of between about 10 to 15 microns. The coated cores are blended with the toner material in an amount of about 1 part toner material per about 100 parts of carrier material. The developer mixture is roll-mill mixed for about 1 hour after which time the triboelectric charge generated on the toner particles is measured as indicated above. The triboelectric value is found to be about +20 micro-coulombs per gram of toner material.
A fresh sample of the developer mixture is used to develop a negatively charged photoconductive surface bearing an electrostatic latent image. It is found that the developer mixture produces images of satisfactory quality with satisfactory background levels below the maximum value of 0.020 deemed acceptable, and image solid area density is good. However, after making about 10,000 copies, it is found that the carrier coating gradually degrades with concomitant loss of triboelectric charging potential and copy quality becomes unsatisfactory.
EXAMPLE II
A developer mixture is prepared by applying a coating solution containing about 10 percent solids comprising about 60 parts of a terpolymer comprising about 70 molar percent of vinylidene fluoride, about 20 molar percent of tetrafluoroethylene, and about 10 molar percent of vinyl butyrate (Fluoropolymer B, available from E. I. duPont Co., Wilmington, Del.) and about 40 parts of styrene methyl methacrylate (60:40) copolymer dissolved in methyl ethyl ketone to steel carrier particles having an average particle diameter of about 250 microns, the carrier cores and the coating solution are simultaneously heated and suspended in a water-jacketed vibratub coating apparatus (available from Vibraslide, Inc., Binghamton, N.Y.). The coating solution is applied to provide about 0.8 percent by weight of the coating material based on the weight of the coated cores. After removal of the solvent, the coated cores are posttreated by heating in a vacuum oven at about 8° C. for about 1 hour and then mixed with the toner material of Example I. The coated cores are blended with the toner material in an amount of about 1 part toner material per about 100 parts of carrier material. The developer mixture is roll-mill mixed for about 1 hour after which time the triboelectric charge generated on the toner particles is measured as indicated above. The triboelectric value is found to be about +20 micro-coulombs per gram of toner material.
A fresh sample of the developer mixture is used to develop a negatively charged photoconductive surface bearing an electrostatic latent image. It is found that the developer mixture produces images of excellent quality with satisfactory background levels well below the maximum value of 0.020 deemed acceptable, and image solid area density is good. After making about 10,000 copies, it is found that carrier coating adhesion is excellent, toner impaction on the carrier coating is insignificant, there is no loss in triboelectric charging values, and copy quality is still excellent.
EXAMPLE III
A developer mixture is prepared by applying a coating solution containing about 10 percent solids comprising about 40 parts of polycaprolactone and 60 parts of polyvinylidene fluoride (Kynar 201, available from Pennwalt Corp., Philadelphia, Pa.) dissolved in methyl ethyl ketone to steel carrier particles having an average particle diameter of about 250 microns. The carrier cores and the coating solution are simultaneously heated and suspended in a water-jacketed vibratub coating apparatus (available from Vibraslide, Inc., Binghamton, N.Y.). The coating solution is applied to provide about 0.8 percent by weight of the coating material based on the weight of the coated cores. After removal of the solvent, the coated cores are post-treated by heating in a vacuum oven at about 80° C. for about 1 hour and then mixed with the toner material of Example I. The coated cores are blended with the toner material in an amount of about 1 part toner material per about 100 parts of carrier material. The developer mixture is roll-mill mixed for about 1 hour after which time the triboelectric charge generated on the toner particles is measured as indicated above. The triboelectric value is found to be about +17 micro-coulombs per gram of toner material.
A fresh sample of the developer mixture is used to develop a negatively charged photoconductive surface bearing an electrostatic latent image. It is found that the developer mixture produces images of excellent quality with satisfactory background levels well below the maximum value of 0.020 deemed acceptable, and image solid area density is good. After making about 10,000 copies, it is found that carrier coating adhesion is excellent, toner impaction on the carrier coating is insignificant, there is no loss in tribroelectric charging values, and copy quality is still excellent.
EXAMPLE IV
A developer mixture is prepared by applying a coating solution containing about 10 percent solids comprising about 55 parts of Fluoropolymer B (available from E. I. duPont Co., Wilmington, Del.), about 25 parts of styrene-methylmethacrylate (60:40) copolymer, and about 20 parts of conductive carbon black particles dissolved in methyl ethyl ketone to steel carrier particles having an average particle diameter of about 250 microns. The carrier cores and the coating solution are simultaneously heated and suspended in a water-jacketed vibratub coating apparatus (available from Vibraslide, Inc., Binghamton, N.Y.). The coating solution is applied to provide about 0.8 percent by weight of the coating material based on the weight of the coated cores. After removal of the solvent, the coated cores are post-treated by heating in a vacuum oven at about 80° C. for about 1 hour and then mixed with the toner material of Example I. The coated cores are blended with the toner material in an amount of about 1 part toner material per about 100 parts of carrier material. The developer mixture is roll-mill mixed for about 1 hour after which time the triboelectric charge generated on the toner particles is measured as indicated above. The triboelectric value is found to be about +15 microcoulombs per gram of toner material.
A fresh sample of the developer mixture is used to develop a negatively charged photoconductive surface bearing an electrostatic latent image. It is found that the developer mixture produces images of excellent quality with satisfactory background levels well below the maximum value of 0.020 deemed acceptable, and image solid area density is good. After making about 10,000 copies, it is found that carrier coating adhesion is excellent, toner impaction on the carrier coating is insignificant, there is no loss in triboelectric charging values, and copy quality is still excellent.
Although specific material and conditions were set forth in the above exemplary processes in making and using the developer materials of this invention, these are merely intended as illustrations of the present invention. Various other toners, carrier cores, substituents and processes such as those listed above may be substituted for those in the examples with similar results.
Other modifications of the present invention will occur to those skilled in the art upon reading the present disclosure. These are intended to be included with the scope of this invention.
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Electrostatographic developer mixtures comprising finely-divided toner particles electrostatically clinging to the surface of carrier particles comprising a core having an outer coating thereon comprising a polyblend of a first polymer possessing negative triboelectric charging characteristics with respect to toner particles and a second polymer which possesses strong adhesive properties with respect to said core. The coated carrier particles have negative triboelectric charging properties and are particularly useful in development of negatively charged photoreceptors. Imaging processes are also disclosed.
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PRIORITY ENTITLEMENT
[0001] This application is entitled to priority based on Provisional Patent Application Ser. No. 61/154,704 filed on Feb. 23, 2009, which is incorporated herein for all purposes by this reference. This application and the Provisional Patent Application have at least one common inventor.
TECHNICAL FIELD
[0002] The invention relates to monitoring the status of device connections in electrical systems for addressing concerns related to system reliability, quality, and safety. More particularly, the invention relates to monitoring the status of systems that include multi-wire interconnects and/or long transmission lines, especially systems that may be deployed in rough environmental conditions.
BACKGROUND OF THE INVENTION
[0003] In systems requiring that multiple loads be electrically coupled to one or more main lines, many connection approaches known in the arts may be used. The load lines may be connected off a main line in a linear transmission line configuration, star configuration, or daisy chain configuration, for example. An example familiar in the arts is a system configuration in which load lines are connected off the main line in a two-wire system with a transmission line configuration. A matrix configuration is also known in the arts, in which loads are connected to main lines using a web of load lines arranged in rows and columns. Those familiar with the arts will recognize that various combinations of such configurations may also be used, such as a linear transmission line connected with one or more star configuration, for example. The complexity of the connections may in some instances be very high and the connections may extend over a very large physical area.
[0004] Regardless which arrangement of system connections are used, the status of device connections in electrical systems can be outside acceptable limits due to poor installation, environment conditions, external conditions, and/or operational errors. If faulty connections are not detected, the individual device or entire system performance can be affected resulting in potential quality, reliability, and/or safety problems. Due to various challenges, monitoring the status of the interconnect system can be difficult at times. For example, when the connection lines are extremely long, on the order of kilometers, it becomes a challenge to find the locations of faulty connections or loads. Other challenges are environmental conditions that could directly contribute to the increased likelihood of faulty loads due to sharp objects, corrosive materials, extreme temperatures, wind, ice, etc. It would therefore be useful to have the capability to conveniently and reliably monitor the status of an interconnect system. One example that demonstrates a need for monitoring a complex interconnect system is in the mining industry, where electronic apparatus is used to control a substantially precisely timed string of detonations. Such a system often uses a multi-wire interconnect where all the device loads are tapped into the same signals at different points of the interconnect system. Marginal interconnect status of the tap wires and connections can affect performance of one or more devices. Conventional integrity check methods often fail to detect such marginal conditions. Due to these and other problems and potential problems, improved status monitoring of an interconnect system would be useful and advantageous in the arts. Reliable yet easy to use detection systems and methods would be particularly beneficial contributions to the art.
SUMMARY OF THE INVENTION
[0005] In carrying out the principles of the present invention, in accordance with preferred embodiments, the invention provides advances in the arts with novel methods and apparatus directed to detecting faulty connections in an electrical system. According to aspects of the invention, preferred embodiments include a basic connector type, a smart connector type, a DC monitoring system, an AC monitoring system, an RF monitoring system, a transmission line monitoring system, and a multi-wire monitoring system. Examples of each of various preferred embodiments of such monitoring systems are described.
[0006] According to one aspect of the invention, an example of a preferred method is disclosed for detecting and reporting faults, and the locations of faults, in an electrical interconnect with a main line and a number of loads. The method includes steps for monitoring signals at one or more device loads and analyzing the monitored signals for determining fault conditions at the device loads. In further steps, faulty loads are isolated from the main lines and load fault conditions are reported to a system master.
[0007] According to another aspect of the invention, in an exemplary embodiment, the method includes steps for monitoring signals at the main lines and analyzing the monitored signals for determining fault conditions at the main lines. In further steps, faults in the main lines are reported to a system master.
[0008] According to another aspect of the invention, an embodiment described includes steps for disabling all but one device load, transmitting a DC signal on the main lines, and measuring voltages at the enabled load. The measured voltages are compared to expected values and the existence of fault conditions is indicated when the voltage measured at that load is less than the expected value.
[0009] According to another aspect of the invention, an embodiment of a method for detecting and reporting faults includes the step of transmitting an AC signal on the main line. The AC signal has one or more pulses of known magnitude, width, and frequency parameters, at least one of which is monitored. Reflected pulse signals at the main line are measured and compared with one or more of the expected parameters for determining whether fault conditions exist.
[0010] According to another aspect of the invention, in an example of a preferred embodiment, a method includes monitoring signals at device loads by sending command signals from a system master to one or more loads to command the loads to enter a diagnostic mode. In a further step, radio frequency (RF) signals are generated and transmitted at one or more of the loads operating in diagnostic mode. The RF signals are detected and received at the main line, and fault conditions at the loads as well as on the main line are identified by comparing parameters of the received RF signals, such as the amplitude, frequency, and phase, with expected values.
[0011] According to another aspect of the invention, an example of a preferred method is disclosed for detecting and reporting faults, and the locations of faults, in an electrical interconnect system having a main line and a number of loads. In the method, one or more additional wire lines connected to one or more device loads is used for monitoring the current flow through the one or more additional wire lines. Fault conditions in one or more device loads are indicated by increases or decreases in current in the one or more additional wire lines relative to the main lines and are reported to a system master.
[0012] According to another aspect of the invention, in an embodiment of the methods described, the steps of monitoring signals at device loads further includes using one or more additional wire lines each connected to one or more device loads through a switch. The steps include monitoring current flow through the one or more additional wire lines while operating all device loads in a quiescent mode in which the loads do not draw current. By switching on each of the device loads individually, current detected in the one or more additional wire line or lines may be used to detect fault conditions.
[0013] According to another aspect of the invention, a preferred embodiment of a system for detecting faults, reporting faults, and detecting the locations of faults in an electrical interconnect system having a main line and a plurality of device loads is disclosed. The system includes monitoring modules at device loads for monitoring signals at the load lines and analyzing modules for determining fault conditions at the device loads based on the monitored signals. A communication module is provided for reporting fault conditions and locations to a system master.
[0014] According to yet another aspect of the invention, a preferred embodiment of the fault detecting system provides one or more monitoring modules at the main line for monitoring signals at the load lines and main line. Also included are one or more analyzing modules at the main line for determining fault conditions at device loads and main line based on the monitored signals. Communication modules at the main line for reporting fault conditions at the device loads or at the main line to a system master.
[0015] According to yet another aspect of the invention, in a preferred embodiment of a electrical interconnect status monitoring system, a DC transmitter is included for transmitting the DC signals from the main line to device loads for monitoring and analyzing fault conditions.
[0016] According to another aspect of the invention, a preferred embodiment of a electrical interconnect status monitoring system includes an AC transmitter for transmitting AC signals from the main line to device loads for use in monitoring and analyzing fault conditions.
[0017] According to another aspect of the invention, preferred embodiments are described in which one or more RF transmitters at one or more device loads in the system may be used for transmitting RF signals to monitoring devices at the main line.
[0018] The invention has advantages including but not limited to providing one or more of the following features; improved accuracy and safety in monitoring the status of device connections in electrical systems, including the ability to test and monitor connections without fully activating the system. These and other advantageous features and benefits of the present invention can be understood by one of ordinary skill in the arts upon careful consideration of the detailed description of representative embodiments of the invention in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention will be more clearly understood from consideration of the following detailed description and drawings in which:
[0020] FIG. 1 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method utilizing a resistance placed between the load and the main line for the purpose of fault detection;
[0021] FIG. 2 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method using an ASIC placed between the load and the main line for the purpose of fault monitoring;
[0022] FIG. 3 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method with a DC monitoring module for detecting fault conditions;
[0023] FIG. 4 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method using an AC monitoring module for detecting fault conditions;
[0024] FIG. 5 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method utilizing a transmission line configuration for monitoring signals observed on the main line for detecting fault conditions;
[0025] FIG. 6 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method with an RF signal generator and RF detector for detecting fault conditions;
[0026] FIG. 7 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method with an RF signal generator external to the device load paired with an RF signal detector at the load for detecting fault conditions; and
[0027] FIG. 8 is a simplified schematic diagram illustrating an example of a preferred embodiment of an electrical interconnect status monitoring system and method with a wire connected to the load through a switch to one side of a bridge diode placed between the inputs of the load for detecting fault conditions.
[0028] References in the detailed description correspond to like references in the various drawings unless otherwise noted. Descriptive and directional terms used in the written description such as front, back, top, bottom, upper, side, et cetera, refer to the drawings themselves as laid out on the paper and not to physical limitations of the invention unless specifically noted. The drawings are not to scale, and some features of embodiments shown and discussed are simplified or amplified for illustrating principles and features, as well as anticipated and unanticipated advantages of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0029] While the making and using of various exemplary embodiments of the invention are discussed herein, it should be appreciated that the present invention provides inventive concepts which can be embodied in a wide variety of specific contexts. It should be understood that the invention may be practiced with various electronic circuits, systems, system components, and subsystems without altering the principles of the invention. For purposes of clarity, detailed descriptions of functions, components, and systems familiar to those skilled in the applicable arts are not included. In general, the invention provides electrical connection status monitoring of multiple connections within an electrical system, providing capabilities for identifying and locating faulty connections. Preferably, the connection status monitoring may be performed with the system in a test mode, facilitating the making of repairs prior to full activation of the system.
[0030] In one preferred embodiment, illustrated in FIG. 1 , a smart connector 100 placed at the connection point between main lines 102 and device loads 104 includes one or more resistive elements 106 . Optionally, another resistive element 108 is placed between the two input wires of the load 104 for the purpose of detecting short and soft short conditions. In this preferred embodiment, the purpose of the resistors 106 is to provide isolation of the load 104 from the main line 102 . In case of a short in the load 104 , the resistors 106 , prevent the short from disturbing the main line 102 . This maintains functionality of the main line and any other loads also connected to it. During system query, a shorted load cannot respond, while a properly connected load can. This facilitates identifying the failure location.
[0031] Now referring primarily to FIG. 2 , in another preferred embodiment, a smart connector 200 includes an ASIC (Application Specific Integrated Circuit) 202 placed between the main lines 102 and device loads 104 . The purposes of the ASIC 202 is to detect, analyze and report fault conditions associated with the loads 104 or main line 102 . In the case of a short at a load, e.g., 104 , higher currents are pulled from the main line 102 . The ASIC 202 then latches off and isolates the faulty load 104 from the main line 102 . The ASIC 202 also preferably includes a communication module that is used to report which load(s) are faulty once the faulty loads are identified and isolated.
[0032] In another preferred embodiment, an example of which is illustrated in FIG. 3 , an electrical interconnect system 300 using a transmission line configuration 302 includes multiple loads 104 A, 104 B, 104 C, etc., and preferably, multiple DC monitoring modules 304 for monitoring the lines 302 and detecting short and soft short conditions in the loads 104 A, 104 B, 104 C, as shown. The DC monitoring module 304 C, shown in the inset, preferably includes a diagnostic mode to disable all but one load, e.g., 104 C. The enabled load 104 C monitoring module 304 C measures the signals at its inputs, thus determining the status of the connection from the main line 302 to the inputs of the load 104 C, and reports its status to the system master 306 . If a faulty condition exists, the device, e.g. 304 C, would either not communicate back to the master 306 or be disabled, thereby making it known to the master 306 , which load is faulty. Preferably, internal diagnostics 308 B at the load circuitry 304 C is used to detect and report the existence of soft short conditions where a voltage drop can be detected across the faulty load. Preferably, one or more diagnostic modes may be implemented in which selected loads may be placed in an autonomous mode in order to mimic isolation from the main line. This can preferably be achieved by utilizing an internal capacitor to supply the load circuitry operating in diagnostic mode, whereby power from the main line is not required for testing.
[0033] FIG. 4 illustrates a transmission line configuration 400 for an electrical equipment system main line 402 , and AC checks 404 A, 404 B, 404 C . . . , monitoring signals for detecting short and soft short conditions in the loads. AC checks are used to monitor the status of an interconnect system relying on the AC characteristics of the main line and load lines. Preferably, a pulse or group of pulses of defined magnitude, width, and frequency are transmitted on the main line 402 . Each load monitor, e.g., 404 C, measures the resulting signals at its respective inputs, and compares them to a set of fixed expected values, or configurable expected values, and reports back its status to the master 406 . If faulty, the monitoring devices would either not communicate back to the master or be disabled, thereby making it known to the master which loads are faulty. In preferred embodiments of an AC monitoring system, each load would alternatively, report back what it had measured for one or more of pulse width, magnitude, and frequency and allow the master to determine the status of the loads. In presently preferred embodiments, the use of pulse width evaluation is predominant.
[0034] In an example of another preferred embodiment, FIG. 5 illustrates a transmission line configuration 500 for an electrical equipment system, and transmission line monitoring signals observed on the main line that consist of transmitted as well as reflected waveforms for detecting short and soft short conditions in the loads. Using this approach, master circuitry 506 is used to directly monitor the reflections off the main line 502 . Preferably, a signal pulse such as a sine wave or single pulse is transmitted on the main line 502 . The reflected wave returning from the main line 502 is then sensed by the master 506 . The resulting reflected signal is a function of the integrity of the main line 502 . The signal characteristics and time delay of the reflected signal give indications of where faults in the line exist. Preferably in the transmission line approach, a termination impedance may be utilized both on the main line and load lines to optimize the line impedance.
[0035] Now referring primarily to FIG. 6 , an RF monitoring system 600 is illustrated that is capable of detecting short or soft short conditions. Preferably, each load to be monitored is equipped with a module 602 capable of generating an RF signal on the load terminals, and each load and monitoring device may be operated in a diagnostic mode. In the diagnostic mode, a monitoring device RF signal generator transmits one or more RF signals to a nearby RF detector. If a load has a fault such as a short or soft short, the RF detector in turn either receives no signal or a small signal relative to the expected signal for conditions wherein the load is without fault. This technique may also be used for detecting the existence of faults on the main line 604 .
[0036] In another example of an alternative RF monitoring system 700 and method, as depicted in FIG. 7 , an RF signal generator 702 is preferably located external to the loads, and an RF signal detector is located at the load(s) to be monitored. If a monitored load has a soft short or short, the detected RF signal at the load is small, or nonexistent, compared with expected normal signal levels when the circuit is without fault. The monitored load condition can then in turn be reported to indicate the status of particular loads.
[0037] FIG. 8 illustrates a multi-wire monitoring system 800 and method for detecting short or soft short fault conditions. One or more wires 802 is deployed to connect to each of the monitored loads through a switch to one side of one or more bridge diodes 804 placed between the inputs of the load. If one or more faulty loads exists, the current in the additional wire(s) increases or decreases relative to the current in the main line(s) 806 , indicating the existence and location of the faulty loads. Preferably, in a multi-wire monitoring system as described above, each of the monitored load circuits may be independently placed in a quiescent diagnostic mode with no current load. In this mode, only one load circuit has the monitoring switch turned on at any given time. In the event that current is observed in the monitoring wire(s), the presence of a fault is indicated for that particular load.
[0038] The methods and apparatus of the invention provide one or more advantages including but not limited to, electrical interconnect status monitoring efficiency, safety, convenience, and reduced cost. While the invention has been described with reference to certain illustrative embodiments, those described herein are not intended to be construed in a limiting sense. For example, variations or combinations of steps or materials in the embodiments shown and described may be used in particular cases without departure from the invention. Various modifications and combinations of the illustrative embodiments as well as other advantages and embodiments of the invention will be apparent to persons skilled in the arts upon reference to the drawings, description, and claims.
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Disclosed are advances in the arts with novel methods and apparatus for detecting faulty connections in an electrical system. Exemplary preferred embodiments include basic, ASIC, AC, DC, and RF monitoring techniques and systems for monitoring signals at one or more device loads and analyzing the monitored signals for determining fault conditions at the device loads and/or at the main transmission lines. The invention preferably provides the capability to test and monitor electrical interconnections without fully activating the host system.
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This application is a Continuation of application Ser. No. 09/109,735 filed Jul. 2, 1998 now U.S. Pat. No. 5,970,828, which is a continuation of application Ser. No. 08/698,653 filed Aug. 16, 1996 (Issued U.S. Pat. No. 5,791,211), which is a continuation-in-part of application Ser. No. 08/599,948, filed Feb. 14, 1996 (Abandoned).
FIELD OF THE INVENTION
The present invention is directed to a one-piece, completely integral, plastic handle for a folding hand tool set, more particularly, to a one-piece, completely integral, plastic handle containing a plurality of hand tools that permits high levels of torque to be generated without compromising the integrity of the plastic handle.
BACKGROUND OF THE INVENTION
Hand tools are typically discrete items that can be easily misplaced. To overcome this problem, various hand tool set holders have been developed in which a plurality of hand tools is secured in a moveable manner so as to avoid individual tools being lost. However, in order to accommodate a sufficient number of tools into a single holder or container, the overall sizes of the tools tend to be reduced and the handle is often relied upon to transmit torque through the tool to the workpiece.
Various types of handles for tool sets have been developed, such as two-piece metal and plastic handles, and one-piece stamped metal handles. Current metal handles are subject to corrosion and add significant weight and cost to the tool sets. Current two-piece plastic handles lack the strength to transmit higher levels of torque required for certain applications. Finally, one-piece handles, whether metal or plastic can be more expensive to assemble then their two-piece counterparts.
SUMMARY OF THE INVENTION
The present invention is directed to a folding hand tool set having a one-piece, completely integral, plastic handle constructed of a thermoplastic and a plurality of hand tools rotatably mounted thereto. In the preferred embodiment, the thermoplastic is fiber reinforced and the folding hand tool set is capable of transmitting more then 110 Newton·meters of torque without compromising the integrity of the one-piece, completely integral, plastic handle, more preferably more than 120 Newton·meters of torque, and most preferably more than 135 Newton·meters of torque.
The present invention is also directed to a one-piece, completely integral, plastic handle for a folding hand tool set constructed of a thermoplastic. In an embodiment where the thermoplastic is fiber reinforced, the handle can withstand at least 30 Newton·meters of torsional force without compromising the integrity of the handle.
The one-piece, completely integral, plastic handle on the folding hand tool set includes first and second elongated side walls arranged in a generally parallel configuration. The sidewalls are joined along a center portion of an inner surface thereof by a center rib. First and second mounting ends are located on opposite ends of the handle. Outer surfaces of the elongated side walls form a gripping surface. The center rib is positioned to form first and second recesses with the side walls for receiving hand tools along a longitudinal axis of the folding hand tool set. The center rib further includes a first reinforcing web proximate the first mounting end to form a portion of a second recess. A second reinforcing web may be located proximate the second mounting end for forming a portion of the first recess.
The plurality of hand tools is rotatable from a first position within the first or second recesses to a second position at least 270° from the first position. It will be understood that the hand tools may be rotated more or less then 270° without departing from the scope of the present invention. The first and second webs form end stops for the second position of the hand tools. In an embodiment in which a hand tool is rotated approximately 270° against an end stop, the end stop reduces the risk that the tool will collapse into the handle when high levels of torque are applied.
One or more of the hand tools may be separated by a spacer or washer. In the preferred embodiment, the spacer or washer is fixedly engaged with the handle so that torque generated from the rotation of a tool from the first position to the second position is not transmitted to adjacent tools.
The one-piece, completely integral, plastic handle is preferably constructed from fiber reinforced thermoplastics. The fibers are preferably aligned or oriented along the longitudinal axis of the handle. Suitable reinforcing materials include aramid, carbon, glass, polyester or mica fibers, or some combination thereof.
In one embodiment, the gripping surface curves inward toward the center rib proximate the center portion to facilitate gripping by the user. Alternatively, the gripping surface may be straight or curve outward proximately the center portion. The center rib may include a center reinforcing member proximate the center portion of the first and second sidewalls. In one embodiment, the reinforcing member is a `S`-shaped curve in the center rib.
A pair of opposing raised shoulders may be located on opposing inner surfaces of the first and second sidewalls proximate the first and second mounting ends. One or more side wall supports may be located along a portion of an inner surface of a sidewall and a portion of the center rib. The side wall supports may also serve to offset the hand tools from the inner surface of the sidewalls to facilitate removal from the handle. The sidewalls of the handle are preferably curved or bowed outward along the top and bottom edges thereof proximately the center portion so that the height or thickness of the sidewalls is greater at the center then at the mounting ends.
A variety of hand tools may be included in the folding hand tool set of the present invention, including hex wrenches, screwdrivers Torx® drivers, open end wrenches, box end wrenches or some combination thereof.
As used in this application the expression "compromise to the integrity of the handle" shall mean permanent damage such as inelastic deformation, visible cracks, or catastrophic failure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary folding hand tool set with a one-piece, completely integral, plastic handle;
FIG. 2 is a top view of an exemplary one-piece, completely integral, plastic handle for a folding hand tool set;
FIG. 3 is a front view of the handle of FIG. 2;
FIG. 4 is a bottom view of the handle of FIG. 2;
FIG. 5 is a rear view of the handle of FIG. 2;
FIG. 6 is a sectional view of the handle of FIG. 2;
FIG. 7 is a sectional view of the folding hand tool set of FIG. 2 with one of the hand tools rotated approximately 180° from the handle;
FIG. 8 is a bottom view of the exemplary folding hand tool set of FIG. 7;
FIG. 9 is a sectional view of the folding hand tool set of FIG. 1 with one of the tools rotated approximately 270° from the handle;
FIG. 10 is a bottom view of the exemplary folding hand tool set of FIG. 9;
FIG. 11 is a left end view of the handle of FIG. 3;
FIG. 12 is a right end view of the handle of FIG. 3;
FIG. 13 is an alternate embodiment of a one-piece, completely integral, plastic handle for a folding hand tool set;
FIG. 14 is a bottom view of the handle of FIG. 13:
FIG. 15 is a top view of an alternate folding hand tool set utilizing the handle of FIG. 13;
FIG. 16 is a sectional view of the folding hand tool set of FIG. 15;
FIG. 17 is a left end view of the handle of FIG. 13;
FIG. 18 is a right end view of the handle of FIG. 13;
FIG. 19 is a top view of the spacer shown in FIG. 16;
FIG. 20 is a top view of an alternate space shown in FIG. 16;
FIG. 21 is a bottom view of an alternate handle with integrally formed spacers; and
FIG. 22 is a sectional view of a folding hand tool set utilizing the handle of FIG. 21.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of an exemplary folding hand tool set 20 in which a plurality of hand tools 22a-22i are retained to a one-piece, completely integral, plastic handle 24 by fasteners 25, 27. The fasteners 25, 27 preferably are threaded proximately only a distal end thereof. The hand tools 22b-22i are located in a first storage position within the handle 24. The hand tool 22a is rotated to a second extended position approximately 270° from the one-piece. completely integral, plastic handle 24. It will be understood that the hand tool 22a can be rotated approximately 180° to operate similarly to a screwdriver (see FIGS. 7 and 8), or a variety of other positions.
The folding hand tool set 20 is preferably assembled by arranging the tools 22a-22c in an upright position in a fixture to simulate the second extended position 270° relative to the handle 24, such as illustrated in FIG. 1. The tools 22d-22i are located in an upright position in an adjacent fixture to simulate a second extended position 90° relative to the handle 24, so that the handle 24 may be engaged with all of the tools 22a-22i simultaneously. The fasteners 25, 27 are then inserted through the handle 24 and tools 22a-22i and secured. The fasteners 25, 27 preferably do not rotate with the tools 22a-22i.
Although the embodiment illustrated in FIG. 1 is shows with a hex-shaped wrench, it will be understood that a variety of hand tools may be included in the folding hand tool set of the present invention, including screwdrivers, Torx® drivers, open end wrenches, box end wrenches or some combination thereof.
FIGS. 2-5 and 11-12 illustrate an exemplary one-piece, completely integral, plastic handle 24 for retaining a plurality of hand tools, such as illustrated in FIG. 1. As illustrated in FIGS. 2 and 4, the one-piece, completely integral, plastic handle 24 includes a first side wall 26 joined to a second side wall 28 by a center rib 30. The center rib 30 extends along the inside surface 32, 34 of the first and second side walls 26,28 at a center portion 36. The center portion 36 extends generally the full length of the center rib 30 as measured along longitudinal axis L. The distal ends of the first and second side walls 26, 28 form first and second mounting ends 40, 43 for receiving a plurality of hand tools.
The first mounting end 40 includes a pair of holes 42, 44 which are aligned across an opening 46. The outside surface of the second side wall 28 includes a hexagonal recess 48 generally concentric with the hole 42 for receiving a fastener (see FIG. 5). The first side wall 26 includes a circular recess 50 concentric with the hole 44 for receiving the head of a fastener for engagement with the hexagonal fastener in the recess 48 (see FIG. 3). The inside surfaces of the first and second side walls 26, 28 include a pair of opposing raised shoulders 52, 54.
Similarly, the second mounting end 43 includes a pair of opposing holes 60, 62 aligned across an opening 64. The second side wall 28 includes the hexagonal recess 66 generally concentric with the hole 60 for receiving a hexagonal fastener (see FIG. 5). The first side wall 26 includes a circular recess 68 concentric with the hole 62 for receiving the head of a fastener that meets with the hexagonal fastener in the recess 66 (see FIG. 1). The inner surfaces 32, 34 of the first and second side walls 26, 28 respectively, include raised shoulders 70, 72. The shoulders 52, 54, 70, 72 serve to offset the hand tools 22a-22i from the inner surface 32, 34, to provide additional strength to the first and second mounting ends 40, 43 and to maintain the hand tools 22a-22i parallel to a longitudinal axis L during rotation.
Tool size indicators 90, 91, 92 are preferably molded into the center rib 30 of the one-piece, completely integral, plastic handle 24. First and second side wall supports 104, 106 provide additional structural support to the side walls 26, 28, respectively, and transmit force from the side walls 26, 28 to the center rib 30. The side wall supports 104, 106 also space the tools 22a-22i from the inner surfaces 32, 34 of the sidewalls 26, 28 to facilitate removal of the hand tools.
As best illustrated in FIG. 2, the first and second side walls 26, 28 are curved inward toward the center rib 30 generally along the center portion 36. The handle 24 is wider proximate the mounting ends 40, 43. It will be understood that the sidewalls 26. 28 may alternately be straight or curved outward proximate the center portion 36. As best illustrated in FIGS. 3 and 5, the sidewalls 26, 28 of the handle 24 are curved or bowed outward along the top and bottom edges thereof so that the height or thickness of the sidewalls is greater at the center portion 36 then at the mounting ends 40, 43.
The sidewalls 26, 28 have greater thickness at the mounting ends 40, 43 due to the raised shoulders 52, 54, 70, 72, as well as additional thermoplastic material proximate the recesses 48, 50, 66, 68. The greater thickness increases resistance to breakage proximate the first and second mounting ends 40, 43. The narrowness of the handle 24 along the center portion 36 provides for some flexibility in this area.
The curves of the handle 24 enhance comfort for the user but also serves to cantilever some of the torsional forces that are generated when using the tool set 20 from the mounting ends 40, 43 toward the center rib 30, thereby increasing the ultimate strength of the handle 24. Consequently, longitudinal as well as lateral displacement distortion occurs when the forces that are generated at the first and second mounting ends 40, 43 of the handle 24 are transferred toward the center portion 36 of the handle 24.
The center rib 30 has an S-shaped curve 80 proximate the center portion 36 to provide additional strength to the plastic handle 24 (see also FIGS. 7 and 9). The center rib 30 includes a first reinforcing web 82 located proximate the first mounting end 40. The edge of the reinforcing web 82 serves as an end stop 86 for the hand tools 22d-22i. Similarly, the center rib 30 includes a second reinforcing web 84 located proximate the second mounting end 43. The edge of the second mounting web serves an end stop 88 for the hand tools 22a-22c (see FIG. 9). The end stops 86, 88 may be curved or angled to accommodate different diameter tools. For example the end stop 86 is angled more toward the center portion 36 opposite the 1/4 inch tool then opposite the 3/16-inch tool.
Additional tool size indicators 93-98 are molded into the bottom side of the center rib 30, as shown in FIG. 4. A second side wall support 100 may be formed proximately the second side wall 28 along the bottom edge of the center rib 30. Similarly, a first side wall support 102 may be formed opposite the second side wall support 100.
FIG. 5 is a rear view of the one piece plastic handle 24 of FIG. 2. A mounting hole 105 may be provided in the second sidewall 28 for attaching instructional information to the hand tool set 20 and for hanging the tool on a tool belt or tool rack.
FIG. 6 is a sectional view of the handle 24 of FIG. 2 showing the first and second side wall supports 104, 106. It will be understood that the precise shape of the side wall supports may vary considerably without departing from the scope of the present invention.
FIG. 11 is a left end view of the handle 24 of FIG. 3 showing the placement of the first sidewall support 104 and the end stop 86. FIG. 12 is a right end view of the handle 24 of FIG. 3 showing placement of the first sidewall support 102 and the end stop 88.
The present one-piece, completely integral plastic handle 24 is preferably constructed from a fiber reinforced thermoplastic formed by injection molding to form a discrete structure or article. The reinforcing fibers are preferably oriented or aligned generally parallel to the longitudinal axis L during the injection molding process to enhance the strength of the handle 24 using injection molding techniques known in the art. Other fiber orientations may be desirable for some applications. The thermoplastic resists cold, heat and corrosive chemicals while providing a comfortable non-slip grip. It will be understood that a variety of non-reinforced plastics may be used instead of the fiber reinforced thermoplastic, although lower levels of torque are likely.
Thermoplastics known to be suitable for use in the present invention include acrylonitrile-butadiene-styrene, acetal, acrylic, polyamide nylon 6--6, nylon, polycarbonate, polyester, polyether etherketone, polyetheride, polyether sulfone, polyphenylene sulfide, polyphenylene oxide, polystyrene, polysulfone, and styrene acrylonitrile. Suitable reinforcing materials include aramid, carbon, glass, polyester or mica fibers, or some combination thereof. The gripping surface preferably has a slightly course or pebbled surface finish in order to provide a non-slip surface. The hand tools 22a-22i are preferably constructed from high grade tool steel and heat treated to provide maximum torque.
It will be understood that the present handle 24 may be constructed in a variety of sizes, depending upon the number and size of the hand tools and the desired strength of the handle 24. While no specific industry standards exist, common dimensions for handles used in folding hand tool sets are set forth in Table 1 below:
TABLE 1______________________________________ Height of Handle ProfileOverall Handle Length (see FIGS. 3 and 5)______________________________________0.1397-0.1524 m (5.5-6.0 inches) 0.0254-0.0381 m (1-1.5 inches)0.1080 m (4.25 inches) 0.0254 m (1 inch)0.0889 m (3.5 inches) 0.0191 m (0.75 inches)0.0762 m (3 inches) 0.0191 m (0.75 inches)______________________________________
FIGS. 7 and 8 illustrate an exemplary folding hand tool set 20 in which one of the hand tools 22a is rotated approximately 180° from the one-piece, completely integral, plastic handle 24. As illustrated in the sectional view of FIG. 7, the center rib 30, first reinforcing web 82 and end stop 86 form a first recess 74. The center rib 30, second reinforcing web 84 and end stop 88 form a second recess 76. Fastener 25 retains hand tools 22d-22i in the handle 24. Fastener 27 retains the hand tools 22a-22c in the handle 24. As illustrated in FIG. 8, the 1/4" designation 92 is exposed, indicating that the 1/4" hex tool has been rotated from the first storage position inside the first recess 74 to a second extended position. The second side wall support 106 serves to guide the hand tool 22a from the first recess 74 to the second extended position.
FIGS. 9 and 10 illustrate the folding hand tool set 20 of FIGS. 7 and 8 in which the hand tool 22a has been rotated approximately 270° relative to the one-piece, completely integral, plastic handle 24. The hand tool 22a contacts the end stop 88 of the second reinforcing web 84. The end stop 88 serves to retain the hand tool 22a at right angles relative to the handle 24. When rotated 270°, the end stops 86, 88 of the first and second reinforcing webs 82, 84 retain the hand tools at approximately 90° relative to the handle 24, thereby allowing the user to generate the maximum torque while minimizing the possibility that the hand tool will collapse toward the center rib 30 and pinch the user's fingers. The second side wall support 106 serves to guide the hand tool 22a from the first recess 74 to the second extended position. It will be understood that the end stops 86, 88 may be adjusted to permit more than 270° of rotation.
FIGS. 13, 14, 17 and 18 illustrate an alternate one-piece, completely integral, plastic handle 120 for retaining a plurality of hand tools 22a-22i (see FIG. 15). The handle 120 of FIGS. 13 and 14 generally corresponds to the handle of FIG. 2 and 4, except that a plurality of slots 122a-122g are formed in the center rib 124 proximate the reinforcing webs 126, 128.
The slots 122a-122g are designed to receive distal portions 130, 131 of spacers 132, 134 shown in FIGS. 19 and 20, respectively. The spacers 132, 134 each have a center hole 136, 138 through which the fasteners 140, 142 extend (see FIG. 16). The spacers 132, 134 may be constructed from a variety of materials, such as metal or a polymeric material.
The distal portion 130 of the spacer 132 is sized to accommodate the distance between the axis of the fastener 140 and the slots 122c-122g. The distal portion 131 of the spacer 134 is sized to accommodate the distance between the axis of the fastener 142 and the slots 122a-122b. The engagement of the distal portions 130, 131 with the slots 122a-122g prevents the spacers 132, 134 from rotating. Consequently, each of the tools 22a-22i of the folding hand tool set 20' of FIGS. 15 and 16 can be rotated from a first position within one of the recesses 74', 76' to an extended position without transmitting torque to adjacent tools 22a-22i. The fasteners 140, 142 preferably do not rotate with the rotation of the tools 22a-22i. Mechanically isolating each tool 22a-22i facilitates usage of the hand tool 20' with one hand.
FIG. 21 illustrates an alternate one-piece completely integral, plastic handle 150 for retaining a plurality of hand tools 22a-22i, illustrated in FIGS. 22. The handle 150 of FIG. 21 generally corresponds to the handles of FIGS. 2 and 14, except that a plurality of spacers 152a-g are integrally formed in the handle 150. The spacers 152a-g extend from the reinforcing webs 154, 156 of the center rib 158 so that center holes 160 in the spacers 152a-g are aligned with the holes 162, 164, 166, 168 in the handle 150. As illustrated in FIG. 22. fasteners 170, 172 extend through the tools 22a-22i, the center holes 160 and the holes 162-168 in the handle 150. Each of the tools 22a-22i of the folding hand tool set 20" of FIG. 22 can be rotated from a first position within one of the recesses 74", 76" to an extended position without transmitting torque to adjacent tools.
EXAMPLES
Two sizes of a folding hand tool set 20 each having a one-piece, completely integral, plastic handle were compared to various other folding tool set constructions to determine the maximum torque at which the integrity of the handle was compromised. The one-piece, completely integral, plastic handles were constructed of a glass fiber reinforced nylon.
Example 1
A series of hand tools with an overall handle length of approximately 0.1080 m (4.25 inches) and a handle height of approximately 0.0254 m (1.0 inch) were tested. Each hand tool set forth from Table 2 below was placed into a round metal holder that completely encased the handle to within one inch of the tool that was tested. The 1/4" hand tool for each handle was rotated 90° from the handle and placed into a hex-shaped hole in a strain gauge transducer until approximately 1" of the tool remained exposed. When pressure was applied to each handle in a rotational fashion, torque was transmitted to the strain gauge and the value of that torque was digitally displayed on the strain gauge readout. The pressure was increased until that handle was permanently damaged or broken, as summarized in Table 2 below.
TABLE 2______________________________________ Torque at which Torque at which permanent damage handle broke orHand Tool Style was done to handle split apart______________________________________Two-part zinc die cast -- 87.11 Newton-metershandleOne-part stamped metal 74.12 Newton-meters 100.22 Newton-metershandleTwo-part plastic handle -- 95.02 Newton-metersTwo-part metal handle -- 72.88 Newton-metersw/ plastic gripsOne-piece, completely -- 135.69 Newton-metersintegral, plastic handle______________________________________
The one-piece plastic handle transmitted 42.8% more torque then that two-part plastic handle tested and 35.3% more torque then the one-part stamped metal handle.
Example 2
A series of hand tools with an overall handle length of 0.0889 m (3.5 inches) and a handle height of approximately 0.01905 m (0.75 inches) were tested according to the method of Example 1, the results of which are set forth in Table 3 below.
TABLE 3______________________________________ Torque at which Torque at which permanent damage handle broke orHand Tool Style was done to handle split apart______________________________________Two-part zinc die cast -- 62.03 Newton-metershandleOne-part stamped metal -- 88.35 Newton-metershandleTwo-part metal handle w/ -- 59.77 Newton-metersplastic gripsOne-piece, completely -- 130.27 Newton-metersintegral, plastic handle______________________________________
The one-piece, completely integral, plastic handle transmitted 47.5% more torque then the one-part stamped metal handle.
Example 3
A series of handles for various folding hand tool sets with the tools removed were subject to a torsional test, including the present one-piece, completely integral, handle constructed from a glass reinforced nylon. One end of each test handle was gripped to a depth of 0.0254 m (1.0 inch) by a retaining fixture attached to a strain gauge transducer. The other end was gripped to a depth of 0.0254 m (1.0 inch) by a retaining fixture attached to a means for inducing a torque along the length of the handle. When pressure was applied to each handle in a rotational (torsional) fashion, torque was transmitted to the strain gauge and the value of that torque was digitally displayed on the strain gauge readout. The torque was increased until the handle being tested broke, split or collapsed, as summarized in Table 4 below.
TABLE 4______________________________________ Torque at which handle broke, splitHand Tool Style Handle size or collapsed______________________________________Two-part zinc die cast 0.1080 m × 0.0254 m 27.46 Newton-metershandleOne-part stamped metal 0.1080 m × 0.0254 m 21.47 Newton-metershandleOne-piece, completely 0.1080 m × 0.0254 m 39.43 Newton-metersintegral, plastic handleTwo-part zinc die cast 0.0889 m × 0.01905 m 23.16 Newton-metershandleOne-part stamped metal 0.0889 m × 0.01905 m 15.93 Newton-metershandleOne-piece, completely 0.0889 m × 0.01905 m 38.41 Newton-metersintegral, plastic handle______________________________________
As is clear from Table 3, the present one-piece, completely integral, plastic handle of the present invention withstood significantly more torque than prior handle constructions.
The present invention has now been described with reference to several embodiments described herein. It will be apparent to those skilled in the art that many changes can be made in the embodiments without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but only to structures described by the language of the claims and the equivalents to those structures.
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A folding hand tool set having a one-piece, completely integral, plastic handle and a plurality of hand tools rotatably mounted thereto. The one-piece, completely integral, plastic handle is preferably constructed from a fiber reinforced thermoplastic. Spacers may be provided for rotationally isolating the hand tools. The folding hand tool set is capable of transmitting more then 110.0 Newton meters of torque without compromising the integrity of the one-piece, completely integral plastic handle. A one-piece, completely integral, plastic handle for receiving hand tools is also disclosed. The handle can withstand at least 30 Newton meters of torsional force without compromising the integrity of the handle.
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TECHNICAL FIELD
[0001] This invention relates to flexible high power light emitting semiconductor devices.
BACKGROUND
[0002] Conventional light emitting semi-conductor (LES), including light emitting diodes (LEDs) and laser diodes, and LES devices (LESD) and packages containing LESDs have several drawbacks. High power LESDs generate a substantial amount of heat that must be managed. Thermal management deals with problems arising from heat dissipation and thermal stresses, which is currently a key factor in limiting the performances of light-emitting diodes.
[0003] In general, LES devices are commonly prone to damage caused by buildup of heat generated from within the devices, as well as heat from sunlight in the case of outside lighting applications. Excessive heat buildup can cause deterioration of the materials used in the LES devices, such as encapsulants for the LESDs. When LESDs are attached to flexible-circuit laminates, which may also include other electrical components, the heat dissipation problems are greatly increased.
[0004] When LESDs are packaged into sub-mount devices, which are then attached to secondary driver systems such as metal core PCB (MPCB), metal insulated substrate (MIS), Bergquist thermal boards, COOLAM substrates, etc., the thermal performance of the submount depends on the thermal resistance of each element in the structure including the sub-mount device, the secondary driver, and the heat sink. In many cases, the secondary driver limits the thermal performance of sub-mount device. Consequently, there is a continuing need to improve the design of support articles and packages to improve their thermal dissipation properties.
SUMMARY
[0005] At least one aspect of the present invention provides a cost-effective thermal management solution for current and future high power LESD constructions through a robust flexible LESD construction. The ability to dissipate large amounts of heat is needed for the operation of high power LESD arrays. According to at least one embodiment of the present invention, heat dissipation can be managed by integrating the LESDs into a system having a flexible dielectric layer that employs a via or cavity to accomplish better heat management. In at least some embodiment of the present invention, to create the vias or cavities, etching through (for vias) or into (for cavities) the dielectric layer is performed.
[0006] At least one embodiment of the present invention provides a light emitting semiconductor device Z comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having one or both of a first and second via extending through the dielectric layer and a cavity or a third via extending from the first surface to, or toward, the second surface of the dielectric layer, the first conductive layer comprising conductive features in electrical contact with one or both of the first and second vias, the cavity or third via at least partially filled with conductive material the second conductive layer comprising conductive features in electrical contact with one or both of the first and second vias; the cavity, or third via, being configured to receive a light emitting semiconductor. In at least one embodiment, one or both of the first and second vias may be hollow plated vias. In at least one embodiment, the second conductive layer may further comprise a conductive feature aligned with the third via or cavity. In at least one embodiment, the conductive features of the second layer may extend under at least a portion of the third via or cavity and are electrically isolated from each other.
[0007] At least on embodiment of the present invention provides a support article Y comprising a flexible dielectric layer having a first major surface and having a second major surface with a conductive layer thereon, the dielectric layer having at least two adjacent cavities or vias extending from the first major surface toward, or to, the second major surface, the two or more cavities or vias each configured to receive one or more bottom contacts of an LES package mounted on the support article, wherein contacts received by a single cavity or via have the same, or a neutral, polarity. In at least one embodiment, the conductive layer on the second major surface of the dielectric layer comprises a conductive feature disposed beneath each via. In at least one embodiment, the first major surface of the dielectric layer has a conductive layer thereon. In at least one embodiment, the conductive layer on the first major surface of the dielectric layer extends into the cavities or vias. In at least one embodiment, the cavities or vias contain conductive material.
[0008] At least on embodiment of the present invention provides a flexible LESD system X comprising an embodiment of light emitting semiconductor device Z and an embodiment of support article Y wherein the conductive features of the second conductive layer of the light emitting semiconductor device make one or both of electrical and thermal connections in the cavities or vias of the support article.
[0009] At least on embodiment of the present invention provides a flexible LESD system V comprising an embodiment of light emitting semiconductor device Z and an embodiment of a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface, the dielectric layer having at least one cavity, or via, extending from the second major surface toward, or to, the first major surface, the at least one cavity, or via, containing conductive material, the first conductive layer comprising a first conductive feature disposed atop the cavity, or via, and at least one second conductive feature disposed adjacent the first conductive feature. In at least one embodiment, a cavity, or via, containing conductive material is disposed under the at least one second conductive feature of the support article. In at least one embodiment, the second major surface of the flexible dielectric layer of the support article has a second conductive layer thereon.
[0010] At least on embodiment of the present invention provides a flexible LESD system U comprising an embodiment of light emitting semiconductor Z and an embodiment of a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having at least one cavity or via extending from the first major surface toward, or to, the second major surface and containing conductive material that form at least two electrically isolated conductive features. In at least one embodiment, one or both conductive features of the light emitting semiconductor device comprises a protrusion and at least one of the electrically isolated features comprises an indentation configured to receive the protrusion of the light emitting semiconductor device.
[0011] Additional embodiments of the present invention are described in the following paragraphs.
[0012] Embodiment A: At least one aspect of the present invention provides a light emitting semiconductor device comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having two vias extending through the dielectric layer and a third via, or a cavity, extending from the first surface to, or toward, the second surface of the dielectric layer, the first conductive layer comprising conductive pads in electrical contact with each of the two vias, the first conductive layer further extending into the third via, or cavity, the second conductive layer comprising conductive pads in electrical contact with each of the two vias and optionally a conductive feature aligned with the via opening in the second surface, or with the cavity floor; the cavity, or via, being optionally filled with conductive material; and a light emitting semiconductor in the via, or cavity. All or a portion of the two vias may comprise hollow plated vias. The third via or cavity may contain conductive material in addition to the conductive material comprising the conductive layer that extends into the third via or cavity.
[0013] Embodiment B: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface, the dielectric layer having at least one cavity, or via, extending from the second major surface toward, or to, the first major surface, the at least one cavity, or via, containing conductive material, the first conductive layer comprising a conductive feature disposed atop the cavity, or via, and conductive pads disposed adjacent the conductive feature.
[0014] Embodiment C: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface, the dielectric layer having three cavities, or vias, extending from the second major surface toward, or to, the first major surface, the three cavities, or vias, containing conductive material, the first conductive layer comprising a conductive feature disposed atop one cavity, or via, and conductive pads disposed adjacent the conductive feature and atop the other two cavities, or vias.
[0015] Embodiment D: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface, the dielectric layer having two cavities, or vias, extending from the second major surface toward, or to, the first major surface, the two cavities, or vias, containing conductive material, the first conductive layer comprising a conductive pads disposed atop each cavity, or via.
[0016] Embodiment E: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface, the dielectric layer having one cavity and one via, extending from the second major surface toward, or to, the first major surface, the cavity and via containing conductive material, the first conductive layer comprising a conductive pads disposed atop each of the cavity and the via.
[0017] Embodiment F: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface, the dielectric layer having one cavity, or via, extending from the second major surface toward, or to, the first major surface, the cavity, or via, containing conductive material, the first conductive layer comprising two conductive pads, one of which is disposed atop the cavity, or via.
[0018] Embodiment G: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having two cavities, or vias, extending from the first major surface toward, or to, the second major surface; the first conductive layer extending into the two cavities, or vias; and the two cavities, or vias, optionally containing additional conductive material.
[0019] Embodiment H: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having two cavities, or vias, extending from the second major surface toward, or to, the first major surface; the second conductive layer extending into the two cavities, or vias; the two cavities, or vias, optionally containing additional conductive material; and the first conductive layer comprising a conductive pad disposed atop each of the cavities, or vias.
[0020] Embodiment I: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having at least one cavity, or via, extending from the first major surface toward, or to, the second major surface; the first conductive layer extending into the at least one cavity, or via; and the at least one cavity, or via, containing a conductive feature and two conductive pads, the conductive pads electrically insulated from each other and from the conductive feature.
[0021] Embodiment J: At least one aspect of the present invention provides a flexible LESD system comprising the light emitting semiconductor device of Embodiment A and the support article of Embodiment B or C wherein the conductive pads of the second conductive layer of the flexible light emitting semiconductor device are electrically and thermally connected to the conductive pads of the first conductive layer of the support article and the conductive feature of the second conductive layer of the light emitting semiconductor device is thermally connected to the conductive feature of the first conductive layer of the support article.
[0022] Embodiment K: At least one aspect of the present invention provides a flexible LESD system comprising the light emitting semiconductor device of Embodiment A and the support article of Embodiments D, E, F, or H wherein the conductive pads of the second conductive layer of the light emitting semiconductor device are one or both of electrically and thermally connected to the conductive pads of the first conductive layer of the support article.
[0023] Embodiment L: At least one aspect of the present invention provides a flexible LESD system comprising the light emitting semiconductor device of Embodiment A and the support article of Embodiment G wherein the conductive pads of the second conductive layer of the light emitting semiconductor device are one or both of electrically and thermally connected to the conductive material in the cavities, or vias, of the support article.
[0024] Embodiment M: At least one aspect of the present invention provides a system comprising the light emitting semiconductor device of Embodiment A and the support article of Embodiment I wherein the conductive pads of the second conductive layer of the light emitting semiconductor device are electrically and thermally connected to the conductive pads of the first conductive layer of the support article and the conductive feature of the second conductive layer of the light emitting semiconductor device is thermally connected to the conductive feature of the first conductive layer of the support article.
[0025] Embodiment N: At least one aspect of the present invention provides a light emitting semiconductor device comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having a cavity, or via, extending from the first major surface toward, or to, the second major surface of the dielectric layer, the first conductive layer extending into the cavity, or via; the cavity, or via, being optionally filled with additional conductive material; and a light emitting semiconductor in the cavity, or via.
[0026] Embodiment O: At least one aspect of the present invention provides a support article comprising a flexible dielectric layer having a first major surface with a first conductive layer thereon and having a second major surface with a second conductive layer thereon, the dielectric layer having at least one cavity, or via, extending from the first major surface toward, or to, the second major surface; the first conductive layer extending into the at least one cavity, or via; the at least one cavity, or via, optionally containing additional conductive material.
[0027] Embodiment P: At least one aspect of the present invention provides a flexible LESD system comprising the light emitting semiconductor device of Embodiment N and the support article of Embodiment O wherein the second conductive layer of the light emitting semiconductor device are one or both of electrically and thermally connected to the conductive material in the cavities, or vias, of the support article.
[0028] Embodiment Q: At least one aspect of the present invention provides a light emitting semiconductor device of Embodiment N further comprising protrusions extending from the second conductive layer.
[0029] Embodiment R: At least one aspect of the present invention provides a support article of Embodiment O further comprising indentation in conductive layer or conductive material in the cavity, or via.
[0030] Embodiment S: At least one aspect of the present invention provides a flexible LESD system comprising the light emitting semiconductor device of Embodiment Q and the support article of Embodiment R, wherein the protrusions extending from the second conductive layer of the light emitting semiconductor device fit into the indentation in the conductive layer or conductive material in the cavity, or via, of the support article.
[0031] As used in this application:
[0032] “LES” means light emitting semiconductor(s), including light emitting diodes and laser diodes;
[0033] “LESD” means light emitting semiconductor devices, including light emitting diode device(s) and laser diode device(s); an LESD may be a bare LES die construction, a complete packaged LES construction, or an intermediate LES construction comprising more than the bare die, but less than all the components for a complete LES package, such that the terms LES and LESD may be used interchangeably and refer to one or all of the different LES constructions; a “discrete LESD” typically refers to one or more LESDs that are “packaged” and ready to function once connected to an electrical source, such as driving circuits including MCPCBs, MISs, etc. Examples of discrete LESDs that may be suitable for use in embodiments of the present invention Golden DRAGON LEDs, available from OSRAM Opto Semiconductors GmbH, Germany; LUXEON LEDs, available from Philips Lumileds Lighting Company, USA; and XLAMP LEDs, available from Cree, Inc., USA, as well as the discrete LESDs described herein and similar devices.
[0034] “support article” means a circuitized flexible article to which one or more discrete LESDs are attached; commercially available alternatives to the support article of the present invention may include metal core printed circuit boards (MCPCBs), metal insulation substrates (MIS), Bergquist thermal boards, and COOLAM thermal substrates;
[0035] “flexible LESD” typically refers to a support article having one or more attached discrete LESD.
[0036] An advantage of at least one embodiment of the present invention is:
[0037] Using the support article of the present invention with a discrete LESD can reduce the overall thermal resistance of light emitting device.
[0038] Using the support article of the present invention with discrete LESDs can allow for quick and cost-effective repair in that, e.g., individual defective LESDs may be easily detached and removed from the vias or cavities and replaced with new LESDs.
[0039] The vias and cavities of the present invention containing conductive material provide excellent Z-axis thermal conductivity.
[0040] The size of the vias and cavities and the surface area of the conductive layers can be tailored to provide optimized thermal resistance values.
[0041] The vias and cavities can be designed to accommodate various LESD electrical contacts.
[0042] The use of a support article of the present invention with LESDs can eliminate the cost associated with conventional LED submounts.
[0043] The flexible LESDs of the present invention can provide a robust, cost-effective thermal management solution for current and future high power LESD constructions.
[0044] The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. The Figures and detailed description that follow below more particularly exemplify illustrative embodiments.
BRIEF DESCRIPTION OF DRAWINGS
[0045] FIG. 1 depicts an embodiment of a support article of the present invention.
[0046] FIGS. 2A-2E depict a process for preparing a support article of the present invention.
[0047] FIG. 3 depicts an embodiment of a support article of the present invention.
[0048] FIGS. 4 and 4 ′ depict embodiments of LESDs of the present invention.
[0049] FIG. 5 depicts an embodiment of an LESD of the present invention attached to an embodiment of a support article of the present invention.
[0050] FIG. 6 depicts an embodiment of a support article of the present invention.
[0051] FIG. 7 depicts an embodiment of a support article of the present invention.
[0052] FIG. 8 depicts an embodiment of a support article of the present invention.
[0053] FIGS. 9A-9B depict embodiments of support articles of the present invention.
[0054] FIGS. 9C-9D depict embodiments of an LESD of the present invention attached to embodiments of support articles of the present invention.
[0055] FIGS. 10A-10B depict embodiments of support articles of the present invention.
[0056] FIGS. 10C-10D depict embodiments of an LESD of the present invention attached to embodiments of support articles of the present invention.
[0057] FIGS. 11 A and 11 A′ depict embodiments of LESDs of the present invention
[0058] FIG. 11B depicts an embodiment of a support article of the present invention.
[0059] FIG. 11C depicts an embodiment of an LESD of the present invention attached to an embodiment of a support article of the present invention.
[0060] FIGS. 12 A and 12 A′ depict embodiments of LESDs of the present invention.
[0061] FIG. 12B depicts an embodiment of a support article of the present invention.
[0062] FIG. 12C depicts an embodiment of an LESD of the present invention attached to an embodiment of a support article of the present invention.
[0063] FIG. 13A depicts an embodiment of a support article of the present invention.
[0064] FIG. 13B depicts an embodiment of an LESD of the present invention.
[0065] FIG. 13C depicts an embodiment of an LESD of the present invention attached to an embodiment of a support article of the present invention.
[0066] FIG. 14 depicts an embodiment of a support article of the present invention with an LESD attached.
[0067] FIG. 15 depicts an embodiment of a support article of the present invention with an LESD attached.
DETAILED DESCRIPTION
[0068] In the following description, reference is made to the accompanying set of drawings that form a part of the description hereof and in which are shown by way of illustration several specific embodiments. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense.
[0069] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein. The use of numerical ranges by endpoints includes all numbers within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5) and any range within that range.
[0070] Unless otherwise indicated, the terms “coat,” “coating,” “coated,” and the like are not limited to a particular type of application method such as spray coating, dip coating, flood coating, etc., and may refer to a material deposited by any method suitable for the material described, including deposition methods such vapor deposition methods, plating methods, coating methods, etc.
[0071] Exemplary embodiments of the present invention as described herein may pertain to a support article comprising vias, which extend all the way through the dielectric layer, thereby forming an opening through the dielectric layer. Alternatively, in some embodiments of the support articles of the present invention, the dielectric layer is not etched all the way through, so that a cavity, having one open end and one closed end, is formed. If this is done, the remaining dielectric material is preferably thin, e.g., up to about 20% to about 30% of the thickness of the dielectric layer. For a dielectric layer having a thickness of about 50 micrometers, a suitable thickness for the remaining dielectric layer is up to about 10 to 15 micrometers (about 20% to about 30% of the total dielectric thickness), in some embodiments, preferably about 1 to about 5 microns, so that it will not significantly inhibit heat transfer. It may be desirable to retain this thin layer of dielectric material, for example, to provide structural integrity, to manage CTE mismatches of adjacent material, or to provide an electrical barrier between electrically conductive feature or layers. Throughout this description, it is intended that all embodiments described with vias have equivalent embodiments with cavities, and vice versa, unless such an alternate embodiment would be physically impossible. When substituting a via for a cavity, or more particularly when substituting a cavity for a via, modifications to the embodiments may be required to establish suitable electrical connections and paths. In at least some embodiments of the present invention, the conductive material within a cavity or via may comprise in whole or in part a portion of a conductive layer that extends from a surface of the flexible dielectric layer into the cavity or via.
[0072] Although the embodiments herein typically describe a single LESD or a single site on a support article for attaching an LESD, it is to be understood that the invention covers multiple LESDs and support articles with multiple sites for attaching LESDs. Additionally, the embodiments herein may include additional cavities or vias throughout the dielectric layer, for example, adjacent to the attached LESDs, to provide additional heat dissipation features.
[0073] Any suitable dielectric layer material may be used to form an embodiment of the present invention having a cavity in place of a via. Suitable methods for forming cavities include essentially the same methods as for forming a via except that methods that cannot be controlled sufficiently to leave a remaining layer of unetched dielectric material are not suitable.
[0074] At least one embodiment of a support article 2 of the present invention is illustrated in FIG. 1 , which shows a flexible dielectric layer 12 having at least one via 10 filled with conductive material 20 , which may be copper or other conductive materials. Via 10 extends through dielectric layer 12 and may be any suitable shape, e.g., circular, oval, rectangular, serpentine, a channel, a grid (e.g., forming islands of dielectric layer separated by a continuous pattern of overlapping channels), etc. For example, if the via is channel-shaped or grid-shaped, a continuous path of conductive material 20 can be located within the outer confines of dielectric layer 12 . The flexible dielectric layer 12 has first and second major surface. Top conductive layer 17 is disposed on the first major surface of dielectric layer 12 and may be patterned to include a conductive feature 22 , which may be an electrically isolated conductive feature, on which feature LESD 24 is disposed. LESD 24 can be attached, directly, or indirectly, to conductive feature 22 using a known die bonding method such as eutectic, solder, adhesive, and fusion bonding. LESD 24 may be wire bonded through conductive pads 26 and 28 to electrically conductive circuits also patterned in top conductive layer 17 . In at least some embodiments of the invention, conductive pads 26 , 28 (as well as 426 , 426 ′, 428 , and 428 ′) are a particular type of conductive feature. They may be patterned features of top or bottom conductive layers 16 or 17 and may comprise Cu. Alternatively, they may comprise a different material such as Au, AuSn, AuGe, or other suitable materials. They typically provide at least an electrical connection and may optionally provide a thermal connection, as opposed to other conductive features, which might only provide a thermal connection in some embodiments. In some embodiments, a passivation or bonding layer is located beneath LESD 24 to facilitate bonding LESD 24 to an underlying layer. In at least one embodiment, thermally conductive layer 30 is attached to the support article adjacent the second major surface of dielectric layer 12 , which brings it into contact with conductive material 20 in via 10 . Thermally conductive layer 30 may be any material that is thermally conductive. For example, conductive substrate may be a thermal interface material (TIM), a metal strip, e.g., of copper or aluminum, a heat sink, or other heat transferring or heat absorbing material. Thermally conductive layer 30 may be attached to the support article using a thermally conductive adhesive. The juxtaposition of conductive feature 22 , conductive material 20 in via 10 , and thermally conductive layer 30 allows for efficient dissipation of heat generated by the LESD to thermally conductive layer 30 . In addition, the conductive material in via 10 can provide mechanical support for conductive feature 22 , which is essentially suspended over the opening of via 10 . In an alternate embodiment of the present invention, instead of applying thermally conductive layer 30 to conductive material 20 , an adhesive, e.g., a TIM with adhesive properties, on a liner can be applied to the conductive material 20 , so that the support article can be directly applied, at a later time, to a conductive substrate or a heat sink.
[0075] FIGS. 2A through 2E show a method of making the support article 2 illustrated in FIG. 1 . Top conductive layer 17 is applied and patterned on a first side of flexible dielectric layer 12 ( FIG. 2A ), then via 10 is formed in flexible dielectric layer 12 , extending from a second side to the first side of flexible dielectric layer 12 ( FIG. 2B ), a photoresist mask is applied over top conductive layer 17 , except for the portion exposed by via 10 ( FIG. 2C ), via 10 is filled with conductive material 20 , e.g., by electrodeposition such as electroplating by building up conductive material on the surface of the conductive layer facing the via ( FIG. 2D ), and the photoresist layer is removed ( FIG. 2E ).
[0076] FIG. 3 is an alternate embodiment of the support article of FIG. 1 . The support article 2 of FIG. 3 has two additional vias 36 and 38 extending through dielectric layer 12 beneath conductive pads 26 and 28 and are filled with conductive material 20 , which may be copper or other conductive materials. These vias can acts as both electrodes and heat transfer channels. If the support article has cavities in place of vias 36 and 38 , the cavities can act as heat transfer channels, but would not act as electrodes because they would be insulated from conductive pads 26 and 28 by a thin layer of dielectric material.
[0077] FIG. 4 illustrates an embodiment of an LESD 24 that may be used with the support article 2 of FIG. 1 . LESD 24 has many of the same or similar components as support article 2 . The flexible dielectric layer 412 has first and second major surface. Vias 410 , 436 , and 438 extend through dielectric layer 412 from the first to second surfaces and may be any suitable shape. Vias 410 , 436 , and 438 may be fully filled, as shown, or partially filled with conductive material 420 , which may be copper or other suitable conductive materials. Top conductive layer 417 is disposed on the first major surface of dielectric layer 412 and bottom conductive layer 416 is disposed on the second major surface of flexible dielectric layer 412 . Conductive layer 416 may be patterned to include a conductive feature 422 , which may be an electrically isolated conductive feature, and conductive features 430 and 432 , which may be electrically connected to conductive pads 426 and 428 through vias 436 and 438 , respectively. LES 424 can be attached, directly, or indirectly (e.g., through conductive material 420 ), to conductive feature 422 using a known die bonding method such as eutectic, solder, adhesive, and fusion bonding. Top conductive layer 417 may include conductive pads 426 and 428 . LES 424 may be wire bonded to conductive pads 426 and 428 . Conductive pads 426 , 428 may comprise Au, AuSn, AuGe, or other suitable materials. In some embodiments, a passivation or bonding layer is located beneath LES 424 to facilitate bonding LES 424 to an underlying layer.
[0078] FIG. 4 ′ illustrates and LESD 24 similar to the LESD of FIG. 4 except for several modified features: Vias 436 ′ and 438 ′ have hollow plated vias, i.e., at least a portion of the via has plated walls but is not fully filled with conductive material. Via 410 ′ has conductive material 420 on its walls, but none on conductive feature 422 . This can be accomplished, for example, by creating conductive feature 422 after conductive material 420 is applied to the walls of via 410 ′. Conductive pads 426 ′ and 428 ′ are located at (or around) the top edge of vias 436 ′ and 438 ′. LES 424 sits directly on conductive feature 422 . Bottom conductive layer 416 is optionally thicker than top conductive layer 417 .
[0079] FIG. 5 illustrates the LESD 24 of FIG. 4 attached to the support article 2 of FIG. 1 . In this embodiment, conductive features 430 and 432 are attached by solder 34 to conductive pads 26 and 28 , respectively, to establish an electrical (and thermal) path and conductive feature 422 is attached by solder 34 to conductive feature 22 to establish a thermal path.
[0080] FIG. 6 illustrates an embodiment of support article 2 having a flexible dielectric layer 12 having two vias 36 and 38 extending therethrough beneath conductive pads 26 and 28 , respectively, formed in top conductive layer 17 . Vias 36 and 38 are filled with conductive material 20 , which may be copper or other conductive materials. These vias can act as both electrodes and heat transfer channels. If the support article has cavities in place of vias 36 and 38 , the cavities can act as heat transfer channels, but would not act as electrodes because they would be insulated from conductive pads 26 and 28 by a thin layer of dielectric material. An optional thermally conductive layer 30 , which may comprise a thermal interface material (TIM) is shown in FIG. 6 .
[0081] FIG. 7 illustrates an embodiment of support article 2 similar to that of FIG. 6 except that there is a via 36 extending through dielectric layer 12 under conductive pad 26 and a cavity 38 ′ under conductive pad 28 . In this configuration, via 36 would be electrically connected to conductive pad 26 , cavity 38 ′ would not be electrically connected to pad 28 , but both would via 36 and cavity 38 ′ would act as heat transfer channels.
[0082] FIG. 8 illustrates an embodiment of support article 2 similar to that of FIGS. 6 and 7 except that there is only a via 36 extending through dielectric layer 12 under conductive pad 26 . There is no via or cavity under conductive pad 28 . An optional conductive substrate 30 , e.g., a TIM layer, may be attached to the second surface of dielectric layer 12 .
[0083] FIGS. 9A and 9B illustrate embodiments of support article 2 in which the cavities 11 ( FIG. 9A ) or vias 10 ( FIG. 9B ) extend from the first side to the second side of dielectric layer 12 . FIG. 9A includes bottom conductive layer 16 on the second surface of dielectric layer 12 and top conductive layer 17 on the first surface of dielectric layer 12 . Top conductive layer 17 is patterned on the first surface of dielectric layer 12 and extends into cavities 11 . Cavities 11 may contain additional conductive material (not shown). Bottom conductive layer 16 may be patterned or unpatterned and is electrically insulated from cavities 11 . FIG. 9B includes bottom conductive layer 16 on the second surface of dielectric layer 12 and top conductive layer 17 on the first surface of dielectric layer 12 . Top conductive layer 17 is patterned on the first surface of dielectric layer 12 and extends into vias 10 . Vias 10 extend entirely through dielectric layer 12 and may contain additional conductive material (not shown). Bottom conductive layer 16 is patterned at least to electrically isolate the vias 10 from one another. FIGS. 9C and 9D illustrate the support articles 2 of FIGS. 9A and 9B , respectively, to which LESDs 24 have been attached by solder bonding conductive features 430 and 432 into cavities 11 or vias 10 using solder 34 (shown before reflow). An optional thermally conductive layer (not shown), e.g., a TIM layer, may be attached to bottom conductive layer 16 . The embodiments illustrated in FIGS. 9C and 9D , in which solder 34 (not shown to scale) is placed in cavities 11 or vias 10 provide the additional advantage of a level solder pad. When the solder in the cavities 11 or vias 10 is reflowed, it is held in place by the walls of the cavities or vias and forms a level surface to which solder bonding features 430 and 432 may be attached (as illustrated in FIGS. 14 and 15 ).
[0084] FIGS. 10A and 10B illustrate embodiments of support article 2 in which the cavities 11 ( FIG. 10A ) or vias 10 ( FIG. 10B ) extend from the second side to the first side of dielectric layer 12 . FIG. 10A includes conductive layer 16 on the second surface of dielectric layer 12 and top conductive layer 17 on the first surface of dielectric layer 12 . Bottom conductive layer 16 is patterned on the second surface of dielectric layer 12 and extends into cavities 11 . Cavities 11 may contain additional conductive material (not shown). Top conductive layer 17 is patterned to form conductive pads 26 and 28 to which LESDs may be attached. These conductive pads are electrically insulated from cavities 11 . FIG. 10B includes conductive layer 16 on the second surface of dielectric layer 12 and top conductive layer 17 on the first surface of dielectric layer 12 . Conductive layer 16 is patterned on the second surface of dielectric layer 12 and extends into vias 10 . Vias 10 extend entirely through dielectric layer 12 and may contain additional conductive material (not shown). Top conductive layer 17 is patterned to form conductive pads 26 and 28 to which LESDs may be attached. These conductive pads are electrically connected to vias 10 . FIGS. 10C and 10D illustrate the support articles 2 of FIGS. 10A and 10B , respectively, to which LESDs 24 have been attached by solder bonding conductive features 430 and 432 to conductive pads 26 and 28 with solder 34 . An optional thermally conductive layer 30 , e.g., a TIM layer, may be attached to conductive layer 16 and conductive material 32 , e.g., a TIM, may be placed into vias 10 and cavities 11 as illustrated in FIGS. 10C and 10D . As illustrated in FIGS. 10C and 10D , if conductive layer 30 comprises conformable material, it may flow into, or be pressed into, cavities 11 or vias 10 thereby allowing the application of conductive layer 30 and conductive material 32 in a single step. Alternatively, conductive material 32 may comprise a different (or the same) material than conductive layer 30 and may be applied in a different step.
[0085] FIG. 11A illustrates an embodiment of an LESD of the present invention similar to the LESD of FIG. 4 except that the LESD 24 of FIG. 11A has a cavity 411 instead of a via. FIG. 11 A′ illustrates an embodiment of an LESD 24 of the present invention similar to the LESD of FIG. 11A with some exceptions. In FIG. 11 A′, LES 424 has both a top and bottom contact such that only one wire bond is required. Wire bond 408 connects the top contact of LES 424 to conductive pad 426 ′, which is electrically connected to solder bonding features 430 through via 436 ″. The bottom contact of LES 424 is connected to conductive pad 428 ′ through top conductive layer 417 including the portion of top conductive layer 417 extending into cavity 411 . Conductive pad 428 ′ is electrically connected to solder bonding feature 432 through via 438 ″. Vias 436 ″ and 438 ″ comprise in part hollow plated vias, i.e., at least a portion of the via has plated walls but is not fully filled with conductive material. However, in contrast to the hollow plated vias 436 ′ and 438 ′ of FIG. 4 ′, vias 436 ″ and 438 ″ have conductive material filling the bottom portion of the via. This can be accomplished, for example, by applying bottom conductive layer 416 prior to depositing conductive material in the vias. Conductive pads 426 ′ and 428 ′ are located at (or around) the top edge of vias 436 ′ and 438 ′. Bottom conductive layer 416 is optionally thicker than top conductive layer 417 . FIG. 11B illustrates an embodiment of support article 2 in which cavity 11 extends from the first to the second surface of dielectric layer 12 , conductive feature 22 is located within cavity 11 and conductive pads 26 and 28 are patterned to extend into cavity 11 . Bottom conductive layer 16 may optionally be on the second surface of dielectric layer 12 and an optional thermally conductive layer 30 , e.g., a layer of TIM (not shown), may optionally be applied to conductive layer 16 and/or the second surface of dielectric layer 12 . FIG. 11C illustrates the support article of FIG. 11B with LESD 24 of FIG. 11A attached to conductive pads 26 and 28 and conductive feature 22 within cavity 11 . In this embodiment, the height of LESD 24 above the height of the support article 2 can be minimized to keep the overall height of the article low.
[0086] FIG. 12A illustrates an LESD 224 that may be placed in via 10 of support article 2 of FIG. 12B . LESD 224 includes cavity 411 that extends from the first to the second surface of dielectric layer 412 . Top conductive layer 417 is patterned on the first surface of dielectric layer 412 and extends into cavity 411 . Bottom conductive layer 416 may optionally be on the second surface of dielectric layer 412 . LES 424 has both a top and bottom contact such that only one wire bond is required. Wire bond 408 connects the top contact of LES 424 to conductive pad 426 , which is electrically connected to solder bonding features 430 through via 466 . The bottom contact of LES 424 is connected to conductive pad 428 through conductive material 420 (e.g., solder or copper) and the portion of top conductive layer 417 extending into cavity 411 . Conductive pad 428 is electrically connected to solder bonding feature 432 through via 468 . A gap 440 separated solder bonding features 430 and 432 . FIG. 12 A′ illustrates an LESD 224 similar to that of the LESD of FIG. 12A . The LESD of FIG. 12 A′ differs from that of FIG. 12A in that it comprises via 410 instead of cavity 411 and there is no via 468 and no solder bonding pad 432 . Instead, the bottom contact of LES 424 is electrically connected to conductive feature 422 (which serves the purpose of missing solder bonding feature 432 in this embodiment) directly through the conductive material 420 (and the portion of top conductive layer 417 extending into via 410 ) located in via 410 . FIG. 12B illustrates an embodiment of support article 2 in which via 10 extends from the first to the second surface of dielectric layer 12 . Top conductive layer 17 is patterned on the first surface of dielectric layer 12 and extends into via 10 . Bottom conductive layer 16 may optionally be on the second surface of dielectric layer 12 and a thermally conductive layer (not shown), e.g., a layer of TIM, may optionally be applied to bottom conductive layer 16 and/or the second surface of dielectric layer 12 . A physical gap 40 is formed in bottom conductive layer 16 and the conductive material in via 10 so that the bottom contacts of an LES placed in via 10 will be electrically separated. FIG. 12C illustrates LESD 224 of FIG. 12A in via 10 of the support article of FIG. 12B . Gaps 1240 and 40 align. In this embodiment, the height of LESD 224 above the height of the support article 2 can be minimized to keep the overall height of the article low. Optional thermally conductive layer 30 is shown.
[0087] FIG. 13A illustrates a modified embodiment of the LESD 224 of FIG. 12A having protrusions 440 , 442 extending from solder bonding features 430 , 432 of bottom conductive layer 216 , respectively. FIG. 13B illustrates a modified embodiment of the support article 2 of FIG. 12B in which via 10 includes notches 40 , 42 for making electrical and mechanical contact with mating protrusions 440 , 442 of LESD 224 . FIG. 13C illustrates LESD 224 of FIG. 13A in via 10 of the support article 2 of FIG. 13B .
[0088] Although the embodiments of FIGS. 11C , 12 C, and 13 C show a single LESD in the cavity or via of the support article, the vias or cavities may be made to hold multiple LESDs.
[0089] FIG. 14 illustrates an embodiment of support article 2 in which two vias 10 extend from the top surface to the bottom surface of dielectric layer 12 . Bottom conductive layer 16 is on the bottom surface of dielectric layer 12 and there is no conductive layer on the top surface of dielectric layer 12 . Conductive layer 16 is patterned on the bottom surface of dielectric layer 12 and includes conductive features 18 , electrically isolated from each other and two of which are located beneath vias 10 . Vias 10 contain conductive material 20 , which may be, for example, solder. A flip chip LESD 24 is attached to support article 2 by the conductive material 20 in vias 10 . In the illustrated embodiment, a solder mask 21 is applied over conductive layer 16 . A reflective solder mask 22 may optionally be applied to the first surface of support article 2 , including under LESD 24 (not shown). The embodiment of FIG. 14 illustrates that if conductive material 20 in vias 10 comprises solder paste or other conductive material that can be reflowed, it provides the additional advantage of a level solder pad. When solder in the vias 10 is reflowed, it is held in place by the walls of the vias and forms a level surface to which flip chip LESD 24 may be attached. The two vias 10 act as anode and cathode electrodes for the flip chip LESD 24 . An optional thermally conductive layer, which may comprise a TIM, may be attached to conductive layer 16 instead of, or in addition to, the solder mask. The thermally conductive layer may be used to attach the support article 2 to a substrate such as a flexible metal foil, a rigid metal layer, or a heat sink. These substrates may be made from any suitable material, but are typically copper or aluminum.
[0090] FIG. 15 illustrates an embodiment of support article 102 in which three vias 110 extend from the top surface to the bottom surface of dielectric layer 112 . Conductive layer 116 is on the bottom surface of dielectric layer 112 and there is no conductive layer on the top surface of dielectric layer 112 . Conductive layer 116 is patterned on the bottom surface of dielectric layer 112 and includes conductive features 118 , electrically isolated from each other and three of which are located beneath vias 110 . Vias 110 contain conductive material 120 , which may be, for example, solder. A flip chip LESD 124 is attached to support article 102 by the conductive material 120 in vias 110 . In the illustrated embodiment, a solder mask 121 is applied over conductive layer 116 . A reflective solder mask 122 may optionally be applied to the first surface of support article 102 , including under LESD 24 (not shown). In the same manner as the embodiment illustrated in FIG. 14 , if conductive material 120 comprises solder paste or other conductive material that can be reflowed, it provides the additional advantage of a level solder pad. When the solder in the vias 100 is reflowed, it is held in place by the walls of the vias and forms a level surface to which flip chip LESD 124 may be attached. In at least one embodiment of the present invention, the outer vias 110 act as anode and cathode electrodes and the inner via 110 acts as a thermal via to improve heat transfer away from the flip chip LESD 124 through its center contact pad. An optional thermally conductive layer 126 , which may comprise a TIM layer, is attached to solder mask 121 . The thermally conductive layer 126 may be used to attach the support article 2 to a substrate 128 such as a flexible metal foil, a rigid metal layer, or a heat sink. These substrates may be made from any suitable material, but are typically copper or aluminum.
[0091] Each via 10 and 110 of support articles 2 and 102 of FIGS. 14 and 15 connects with one contact of an LESD 24 or 124 having to two or more contacts. In some embodiments in which the LESD has, e.g., two contacts having the same polarity or two contacts wherein one contact is electrically neutral, a single via might connect with the two contact, but a second adjacent via will connect to the contact of the LESD having a polarity opposite to the polarity of a contact connected with the first via.
[0092] Suitable dielectric layers for the present invention include polyesters, polycarbonates, liquid crystal polymers, and polyimides. Polyimides are preferred. Suitable polyimides include those available under the trade names KAPTON, available from DuPont; APICAL, available from Kaneka Texas corporation; SKC Kolon PI, available from SKC Kolon PI Inc.; and UPILEX and UPISEL, available from Ube-Nitto Kasei Industries, Japan. Most preferred are polyimides available under the trade designations UPILEX S, UPILEX SN, and UPISEL VT, all available from Ube-Nitto Kasei Industries. These polyimides are made from monomers such as biphenyl tetracarboxylic dianhydride (BBDA) and phenyl diamine (PDA). In at least one embodiment, the thickness of the dielectric layer is preferably 50 micrometers or less, but may be any thickness suitable for a particular application.
[0093] The dielectric layers may alternatively be materials such as FR4, depending on the application.
[0094] The dielectric layers (substrates) may be initially clad on one or both sides with a conductive layer. If the conductive layer(s) are to be formed into circuits, they may be pre-patterned, or may be patterned during the process of making the support articles. A multilayer flexible substrate (having multiple layers of dielectric and conductive material) may also be used as a substrate. The conductive layers may be any suitable material including copper, gold, nickel/gold, silver, and stainless steel, but are typically copper. The conductive layer may be applied in any suitable manner such as sputtering, plating, chemical vapor deposition, or it may be laminated to the dielectric layer or attached with an adhesive.
[0095] Vias or cavities may be formed in the dielectric layers using any suitable method such as chemical etching, plasma etching, focused ion-beam etching, laser ablation, embossing, microreplication, injection molding, and punching. Chemical etching may be preferred in some embodiments. Any suitable etchant may be used and may vary depending on the dielectric layer material. Suitable etchants may include alkali metal salts, e.g. potassium hydroxide; alkali metal salts with one or both of solubilizers, e.g., amines, and alcohols, such as ethylene glycol. Suitable chemical etchants for some embodiments of the present invention include KOH/ethanol amine/ethylene glycol etchants such as those described in more detail in U.S. Patent Publication No. 2007-0120089-A1, incorporated herein by reference. Other suitable chemical etchants for some embodiments of the present invention include a KOH/glycine etchants such as those described in more detail in co-pending U.S. Provisional Patent Application No. 61/409,791, incorporated herein by reference. Subsequent to etching, the dielectric layers may be treated with an alkaline KOH/potassium permanganate (PPM) solution, e.g., a solution of about 0.7 to about 1.0 wt % KOH and about 3 wt % KMnO4.
[0096] The side wall angles resulting from chemical etching varies, and is most dependent on etch rate, with slower etching rates resulting in shallower side wall angles. Typical side wall angles resulting from chemical etching are about 5° to about 60°, and in at least one embodiment, about 25° to about 28°. For purposes of this application, a sloped side wall means a side wall that is not perpendicular to the horizontal plane of the dielectric layer. Vias or cavities with sloped sidewalls could also be made using methods such as embossing, microreplication, and injection molding. Vias or cavities having sloped sidewalls may also be made with methods such as punching, plasma etching, focused ion-beam etching, and laser ablation; however, with these methods, the side walls typically have a steeper angle, e.g., up to 90°.
[0097] Embodiments of the present invention having vias or cavities with sloped side walls may be preferred because, e.g., for a given thickness of dielectric layer and a given via or cavity diameter nearest a conductive feature, a via having sloped side walls can contain more conductive material that a via having 90° side walls. For example, the opening of a via adjacent a conductive feature typically will be limited by the size of that conductive feature; however, by employing sloped via side walls, the opening at the opposing end of the via may be enlarged to an optimum size such that the via can contain a larger amount of conductive material (to transfer more heat away from the LESD) and the conductive at this opening has a large surface area that can interface more effectively with a heat transferring or absorbing material, such as a thermal interface material (TIM) or a metal substrate, which may be attached to the dielectric layer and conductive-filled vias.
[0098] If the vias in embodiments of the present invention have a conductive layer adjacent one opening, it can be filled with conductive material by electrodeposition, such as electroplating, by building up conductive material on the surface of the conductive layer facing the via.
[0099] Any suitable TIM may be used in embodiments of the present invention. Depending on the embodiment, the TIM may be applied to the support article as a liquid, paste, gel, solid, etc. Suitable methods for applying TIM depend on the properties of the specific TIM, but include precision coating, dispensing, screen printing, lamination etc.
[0100] Suitable methods for curing a curable TIM include UV curing, thermal curing etc.
[0101] The TIM may be coated on, e.g., as a liquid or a semi-solid such as a gel or paste, or may be laminated on in sheet form. A combination of TIMs could be used. For example, in some embodiments, such as those shown in FIGS. 10C and 10D , a first type of TIM may be applied in the vias or cavities and a second type of TIM may be applied to the second major surface of the dielectric layer, which would bring it into contact with the first type of TIM. In some embodiments, the TIM may also be adhesive-based. In such an embodiment, the TIM could adhere directly to the support article on one side and a conductive substrate on the other. A TIM that does not have adhesive properties could be applied to one or both of the substrate article and the conductive substrate with a thermally conductive adhesive. The TIM may be first applied to the substrate article and a conductive substrate applied to the TIM thereafter, or the TIM may be first applied to a conductive substrate and the TIM-coated conductive substrate applied to the substrate article thereafter.
[0102] The discrete LESDs can be made in a batch process or a continuous process such as a roll-to-roll process that is often used in making flexible circuits. Arrays of LESDs can be formed in any desired pattern on the flexible substrate. The LESDs can then be divided as desired, e.g., singulated into individual LESDs, strips of LESDs, or arrays of LESDs, e.g., by stamping or by slitting the substrate. Accordingly, an entire reel of LESDs on a flexible substrate can be shipped without the need for the traditional tape and reel process in which individual LESDs are typically transported in individual pockets of a carrier tape.
[0103] The support articles can also be made in a batch process or a continuous process such as a roll-to-roll process that is often used in making flexible circuits. The support articles can be formed with any desired pattern of LESD attachment sites on the flexible substrate. The support articles can then be divided as desired, e.g., singulated to provide individual LESD attachment sites, strips of LESD attachment sites, or arrays of LESD attachment sites, e.g., by stamping or by slitting the substrate.
[0104] Before or after forming support articles with individual, strips, or arrays of LESD attachment sites, the support articles can be attached to an additional substrate, for example with a thermally conductive adhesive. The thermally conductive adhesive can further facilitate the transfer of heat away from the LESDs, once attached to the support article. The support articles can be attached to any desired substrate, depending on their intended use. The additional substrate may be thermally and/or electrically conductive or may be a semiconductor, ceramic, or polymeric substrate, which may or may not be thermally conductive. For example, the additional substrates can be flexible or rigid metal substrates, such as copper or aluminum, heat sinks, dielectric substrates, circuit boards, etc.
[0105] If the flexible LESDs (comprising both the support article and discrete LESDs) are for use as a lighting strip, they could be enclosed in a waterproof/weatherproof, transparent casing, as described above.
[0106] If the flexible LESDs are in strip or array form, the discrete LESDs may be electrically connected to one or more of the other discrete LESDs in the strip or array. Additional elements such as Zener diodes and Schottky diodes can also be added to the top or bottom surface of the support article, e.g. using direct wafer bonding or flip chip processes. These elements may also be electrically connected to the LESDs.
[0107] In at least one embodiment of the present invention, the flexible LESs are thinner than conventional single or multiple LESD submounts because the LESD sits in a cavity or via in the support article. This enables the flexible LESDs of the present invention to be used in applications with tight volume restrictions, such as cell phones and camera flashes. For example, the support articles of the present invention can provide a package profile of approximately 0.7 to 4 mm, and in some embodiments 0.5 to 2 mm whereas conventional LESD submount profiles are typically greater than 4 mm and are approximately 4.8 mm to 6.00 mm. Moreover, the support articles of the present invention can be flexed or bent to easily fit into a non-linear or non-planar assembly if desired.
[0108] Although specific embodiments have been illustrated and described herein for purposes of description of the preferred embodiment, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the preferred embodiments discussed herein. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.
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Provided is a light emitting semiconductor device comprising a flexible dielectric layer, a conductive layer on at least one side of the dielectric layer, at least one cavity or via in the dielectric substrate, and a light emitting semiconductor supported by the cavity or via. Also provided is a support article comprising a flexible dielectric layer, a conductive layer on at least one side and at least one cavity or via in the dielectric substrate. Further provided is a flexible light emitting semiconductor device system comprising the above-described light emitting semiconductor device attached to the above-described support article.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. Ser. No. 09/306,866, filed May 7, 1999, now U.S. Pat. No. 6,235,048 and titled “Selective Organ Hypothermia Method and Apparatus”, which is a divisional application of U.S. Ser. No. 09/012,287, filed Jan. 23, 1998, titled “Selective Organ Hypothermia Method and Apparatus”, now U.S. Pat. No. 6,051,019.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The current invention relates to selective cooling, or hypothermia, of an organ, such as the brain, by cooling the blood flowing into the organ. This cooling can protect the tissue from injury caused by anoxia or trauma.
2. Background Information
Organs of the human body, such as the brain, kidney, and heart, are maintained at a constant temperature of approximately 37° C. Cooling of organs below 35° C. is known to provide cellular protection from anoxic damage caused by a disruption of blood supply, or by trauma. Cooling can also reduce swelling associated with these injuries.
Hypothermia is currently utilized in medicine and is sometimes performed to protect the brain from injury. Cooling of the brain is generally accomplished through whole body cooling to create a condition of total body hypothermia in the range of 20° to 30° C. This cooling is accomplished by immersing the patient in ice, by using cooling blankets, or by cooling the blood flowing externally through a cardiopulmonary bypass machine. U.S. Pat. No. 3,425,419 to Dato and U.S. Pat. No. 5,486,208 to Ginsburg disclose catheters for cooling the blood to create total body hypothermia However, they rely on circulating a cold fluid to produce cooling. This is unsuitable for selective organ hypothermia, because cooling of the entire catheter by the cold fluid on its way to the organ would ultimately result in non-selective, or total body, cooling.
Total body hypothermia to provide organ protection has a number of drawbacks. First, it creates cardiovascular problems, such as cardiac arrhythmias, reduced cardiac output, and increased systemic vascular resistance. These side effects can result in organ damage. These side effects are believed to be caused reflexively in response to the reduction in core body temperature. Second, total body hypothermia is difficult to administer. Immersing a patient in ice water clearly has its associated problems. Placement on cardiopulmonary bypass requires surgical intervention and specialists to operate the machine, and it is associated with a number of complications including bleeding and volume overload. Third, the time required to reduce the body temperature and the organ temperature is prolonged. Minimizing the time between injury and the onset of cooling has been shown to produce better clinical outcomes.
Some physicians have immersed the patient's head in ice to provide brain cooling. There are also cooling helmets, or head gear, to perform the same. This approach suffers from the problems of slow cool down and poor temperature control due to the temperature gradient that must be established externally to internally. It has also been shown that complications associated with total body cooling, such as arrhythmia and decreased cardiac output, can also be caused by cooling of the face and head only.
Selective organ hypothermia has been studied by Schwartz, et. al. Utilizing baboons, blood was circulated and cooled externally from the body via the femoral artery and returned to the body through the carotid artery. This study showed that the brain could be selectively cooled to temperatures of 20° C. without reducing the temperature of the entire body. Subsequently, cardiovascular complications associated total body hypothermia did not occur. However, external circulation of the blood for cooling is not a practical approach for the treatment of humans. The risks of infection, bleeding, and fluid imbalance are great. Also, at least two arterial vessels must be punctured and cannulated. Further, percutaneous cannulation of the carotid artery is very difficult and potentially fatal, due to the associated arterial wall trauma. Also, this method could not be used to cool organs such as the kidneys, where the renal arteries cannot be directly cannulated percutaneously.
Selective organ hypothermia has also been attempted by perfusing the organ with a cold solution, such as saline or perflourocarbons. This is commonly done to protect the heart during heart surgery and is referred to as cardioplegia. This procedure has a number of drawbacks, including limited time of administration due to excessive volume accumulation, cost and inconvenience of maintaining the perfusate, and lack of effectiveness due to temperature dilution from the blood. Temperature dilution by the blood is a particular problem in high blood flow organs. such as the brain. For cardioplegia, the blood flow to the heart is minimized, and therefore this effect is minimized.
Intravascular, selective organ hypothermia, created by cooling the blood flowing into the organ, is the ideal method. First, because only the target organ is cooled, complications associated with total body hypothermia are avoided. Second, because the blood is cooled intravascularly, or in situ, problems associated with external circulation of blood are eliminated. Third, only a single puncture and arterial vessel cannulation is required, and it can be performed at an easily accessible artery such as the femoral, subclavian, or brachial. Fourth, cold perfusate solutions are not required, thus eliminating problems with excessive fluid accumulation. This also eliminates the time, cost, and handling issues associated with providing and maintaining cold perfusate solution. Fifth, rapid cooling can be achieved. Sixth, precise temperature control is possible.
Previous inventors have disclosed the circulation of a cold fluid to produce total body hypothermia, by placing a probe into a major vessel of the body. This approach is entirely unfeasible when considering selective organ hypothermia, as will be demonstrated below.
The important factor related to catheter development for selective organ hypothermia is the small size of the typical feeding artery, and the need to prevent a significant reduction in blood flow when the catheter is placed in the artery. A significant reduction in blood flow would result in ischemic organ damage. While the diameter of the major vessels of the body, such as the vena cava and aorta, are as large as 15 to 20 mm., the diameter of the feeding artery of an organ is typically only 4.0 to 8.0 mm. Thus, a catheter residing in one of these arteries cannot be much larger than 2.0 to 3.0 mm. in outside diameter. It is not practical to construct a selective organ hypothermia catheter of this small size using the circulation of cold water or other fluid. Using the brain as an example, this point will be illustrated.
The brain typically has a blood flow rate of approximately 500 to 750 cc/min. Two carotid arteries feed this blood supply to the brain. The internal carotid is a small diameter artery that branches off of the common carotid near the angle of the jaw. To cool the brain, it is important to place some of the cooling portion of the catheter into the internal carotid artery, so as to minimize cooling of the face via the external carotid, since face cooling can result in complications, as discussed above. It would be desirable to cool the blood in this artery down to 32° C., to achieve the desired cooling of the brain. To cool the blood in this artery by a 5 C.° drop, from 37° C. down to 32° C., requires between 100 and 150 watts of refrigeration power.
In order to reach the internal carotid artery from a femoral insertion point, an overall catheter length of approximately 100 cm. would be required. To avoid undue blockage of the blood flow, the outside diameter of the catheter can not exceed approximately 2 mm. Assuming a coaxial construction, this limitation in diameter would dictate an internal supply tube of about 0.70 mm. diameter, with return flow being between the internal tube and the external tube.
A catheter based on the circulation of water or saline operates on the principle of transferring heat from the blood to raise the temperature of the water. Rather than absorbing heat by boiling at a constant temperature like a freon, water must warm up to absorb heat and produce cooling. Water flowing at the rate of 5.0 grams/sec, at an initial temperature of 0° C. and warming up to 5° C., can absorb 100 watts of heat. Thus, the outer surface of the heat transfer element could only be maintained at 5° C., instead of 0° C. This will require the heat transfer element to have a surface area of approximately 1225 mm 2 . If a catheter of approximately 2.0 mm. diameter is assumed, the length of the heat transfer element would have to be approximately 20 cm.
In actuality, because of the overall length of the catheter, the water would undoubtedly warm up before it reached the heat transfer element, and provision of 0° C. water at the heat transfer element would be impossible. Circulating a cold liquid would cause cooling along the catheter body and could result in non-specific or total body hypothermia. Furthermore, to achieve this heat transfer rate, 5 grams/sec of water flow are required. To circulate water through a 100 cm. long, 0.70 mm. diameter supply tube at this rate produces a pressure drop of more than 3000 psi. This pressure exceeds the safety levels of many flexible medical grade plastic catheters. Further, it is doubtful whether a water pump that can generate these pressures and flow rates can be placed in an operating room.
BRIEF SUMMARY OF THE INVENTION
The selective organ cooling achieved by the present invention is accomplished by placing a cooling catheter into the feeding artery of the organ. The cooling catheter is based on the vaporization and expansion of a compressed and condensed refrigerant, such as freon. In the catheter, a shaft or body section would carry the liquid refrigerant to a distal heat transfer element where vaporization, expansion, and cooling would occur. Cooling of the catheter tip to temperatures above minus 2° C. results in cooling of the blood flowing into the organ located distally of the catheter tip, and subsequent cooling of the target organ. For example, the catheter could be placed into the internal carotid artery, to cool the brain. The size and location of this artery places significant demands on the size and flexibility of the catheter. Specifically, the outside diameter of the catheter must be minimized, so that the catheter can fit into the artery without compromising blood flow. An appropriate catheter for this application would have a flexible body of 70 to 100 cm. in length and 2.0 to 3.0 mm. in outside diameter.
It is important for the catheter to be flexible in order to ;successfully navigate the arterial path, and this is especially true of the distal end of the catheter. So, the distal end of the catheter must have a flexible heat transfer element, which is composed of a material which conducts heat better than the remainder of the catheter. The catheter body material could be nylon or PBAX, and the heat transfer element could be made from nitinol, which would have approximately 70 to 100 times the thermal conductivity of the catheter body material, and which is also superelastic. Nitinol could also be treated to undergo a transition to another shape, such as a coil, once it is placed in the proper artery. Certain tip shapes could improve heat transfer as well as allow the long tip to reside in arteries of shorter length.
The heat transfer element would require sufficient surface area to absorb 100 to 150 watts of heat. This could be accomplished with a 2 mm. diameter heat transfer tube, 15 to 18 cm. in length, with a surface temperature of 0° C. Fins can be added to increase the surface area, or to maintain the desired surface area while shortening the length.
The cooling would be provided by the vaporization and expansion of a liquid refrigerant, such as a freon, across an expansion element, such as a capillary tube. For example, freon R12 boiling at 1 atmosphere and a flow rate of between 0.11 and 0.18 liter/sec could provide between approximately 100 and 150 watts of refrigeration power. Utilizing a liquid refrigerant allows the cooling to be focused at the heat transfer element, thereby eliminating cooling along the catheter body. Utilizing boiling heat transfer to the expanded fluid also lowers the fluid flow rate requirement to remove the necessary amount of heat from the blood. This is important because the required small diameter of the catheter would have higher pressure drops at higher flow rates.
The catheter would be built in a coaxial construction with a 0.70 mm. inner supply tube diameter and a 2.0 mm. outer return tube diameter. This limits the pressure drops of the freon along the catheter length, as well as minimizing the catheter size to facilitate carotid placement. The inner tube would carry the liquid freon to the tubular heat transfer element at the distal end of the catheter body. If a heat transfer element surface temperature of 0° C. is maintained, just above the freezing point of blood, then 940 mm 2 of surface area in contact with the blood are required to lower the temperature of the blood by the specified 5 C.° drop. This translates to a 2.0 mm. diameter heat transfer tube by 15 cm. in length. To generate 0° C. on the nitinol surface, the freon must boil at a temperature of minus 28° C. It is important to have boiling heat transfer, which has a higher heat transfer coefficient, to maintain the surface temperature at 0° C. There are several freons that can be controlled to boil at minus 28° C., such as a 50/50 mixture of pentafluoroethane and 1,1,1 trifluoroethane or a 50/50 mixture of difluoromethane and pentafluoroethane. The 50/50 mixture of pentafluoroethane and 1,1,1 trifluoroethane would require a flow rate of approximately 7.0 liters/min or 0.52 gram/sec to absorb 100 watts of heat. At this flow rate, the pressure drop along the inner tube is less than 7 psi in 100 cm. of length, and the pressure drop along the outer tube is less than 21 psi in 100 cm. of length.
The inner supply tube of the catheter would be connected to a condenser, fed by the high pressure side of a compressor, and the outer return tube of the catheter would be connected to the low pressure side of the compressor.
The novel features of this invention, as well as the invention itself, will be best understood from the attached drawings, taken along with the following description, in which similar reference characters refer to similar parts, and in which:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a schematic, partially in section, showing a first embodiment of the flexible catheter according to the present invention;
FIG. 2 is a perspective view of a second embodiment of the distal tip of the catheter of the present invention, after transformation;
FIG. 3 is a section view of a third embodiment of the distal tip of the catheter of the present invention, after expansion of the heat transfer element;
FIG. 4 is a partial section view of a fourth embodiment of the distal tip of the catheter of the present invention, after transformation;
FIG. 5 is an elevation view of a fifth embodiment of the distal tip of the catheter of the present invention, before transformation;
FIG. 6 is an elevation view of the embodiment shown in FIG. 5, after transformation to a double helix;
FIG. 7 is an elevation view of the embodiment shown in FIG. 5, after transformation to a looped coil;
FIG. 8 is an elevation view of a sixth embodiment of the distal tip of the catheter of the present invention, showing longitudinal fins on the heat transfer element;
FIG. 9 is an end view of the embodiment shown in FIG. 8;
FIG. 10 is an elevation view of a seventh embodiment of the distal tip of the catheter of the present invention, showing annular fins on the heat transfer element; and
FIG. 11 is an end view of the embodiment shown in FIG. 10 .
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, the apparatus of the present invention includes a flexible catheter assembly 10 , fed by a refrigeration compressor unit 12 , which can include a condenser. The compressor unit 12 has an outlet 14 and an inlet 16 . The catheter assembly 10 has an outer flexible catheter body 18 , which can be made of braided PBAX or other suitable catheter material. The catheter body 18 must be flexible, to enable passage through the vascular system of the patient to the feeding artery of the selected organ. The inner lumen 19 of the catheter body 18 serves as the return flow path for the expanded refrigerant. The catheter assembly 10 also has an inner flexible refrigerant supply conduit 20 , which can be made of nylon, polyimide, nitinol, or other suitable catheter material. The length and diameter of the catheter body 18 and refrigerant supply conduit 20 are designed for the size and location of the artery in which the apparatus will be used. For use in the internal carotid artery to achieve hypothermia of the brain, the catheter body 18 and refrigerant supply conduit 20 will have a length of approximately 70 to 100 centimeters. The catheter body 18 for this application will have an outside diameter of approximately 2.5 millimeters and an inside diameter of approximately 2.0 millimeters, and the refrigerant supply conduit will have an outside diameter of approximately 1.0 millimeter and an inside diameter of approximately 0.75 millimeter. A supply conduit 20 of this diameter will have a refrigerant pressure drop of only approximately 0.042 atmospheres per 100 centimeters. The return flow path through a catheter body 18 of this diameter will have a refrigerant pressure drop of only approximately 0.064 atmospheres per 100 centimeters.
The compressor outlet 14 is attached in fluid flow communication, by known means, to a proximal end of the refrigerant supply conduit 20 disposed coaxially within said catheter body 18 . The distal end of the refrigerant supply conduit 20 is attached to an expansion element, which in this embodiment is a capillary tube 22 having a length of approximately 15 to 25 centimeters. The capillary tube 22 can be made of polyimide or nitinol, or other suitable material, and it can be a separate element attached to the supply conduit 20 , or it can be an integral portion of the supply conduit 20 . For the internal carotid artery application, the capillary tube 22 will have an outside diameter of approximately 0.6 millimeter and an inside diameter of approximately 0.25 millimeter. The expansion element, such as the capillary tube 22 , has an outlet within a chamber of a flexible heat transfer element such as the hollow flexible tube 24 . The tube 24 shown in this embodiment is flexible but essentially straight in its unflexed state. The heat transfer element must be flexible, to enable passage through the vascular system of the patient to the feeding artery of the selected organ. For the internal carotid application the flexible tube 24 will have a length of approximately 15 centimeters, an outside diameter of approximately 1.9 millimeters and an inside diameter of approximately 1.5 millimeters. The heat transfer element also includes a plug 26 in the distal end of the flexible tube 24 . The plug 26 can be epoxy potting material, plastic, or a metal such as stainless steel or gold. A tapered transition of epoxy potting material can be provided between the catheter body 18 and the flexible tube 24 .
A refrigerant, such as freon, is compressed, condensed, and pumped through the refrigerant supply conduit 20 to the expansion element, or capillary tube, 22 . The refrigerant vaporizes and expands into the interior chamber of the heat transfer element, such as the flexible tube 24 , thereby cooling the heat transfer element 24 . Blood in the feeding artery flows around the heat transfer element 24 , thereby being cooled. The blood then continues to flow distally into the selected organ, thereby cooling the organ.
A second embodiment of the heat transfer element is shown in FIG. 2 . This embodiment can be constructed of a tubular material such as nitinol, which has a temperature dependent shape memory. The heat transfer element 28 can be originally shaped like the flexible tube 24 shown in FIG. 1, at room temperature, but trained to take on the coiled tubular shape shown in FIG. 2 at a lower temperature. This allows easier insertion of the catheter assembly 10 through the vascular system of the patient, with the essentially straight but flexible tubular shape, similar to the flexible tube 24 . Then, when the heat transfer element is at the desired location in the feeding artery, such as the internal carotid artery, refrigerant flow is commenced. As the expanding refrigerant, such as a 50/50 mixture of pentafluoroethane and 1,1,1 trifluoroethane or a 50/50 mixture of difluoromethane and pentafluoroethane, cools the heat transfer element down, the heat transfer element takes on the shape of the heat transfer coil 28 shown in FIG. 2 . This enhances the heat transfer capacity, while limiting the length of the heat transfer element.
A third embodiment of the expansion element and the heat transfer element is shown in FIG. 3 . This embodiment of the expansion element is an orifice 30 , shown at the distal end of the refrigerant supply conduit 20 . The outlet of the orifice 30 discharges into an expansion chamber 32 . In this embodiment, the heat transfer element is a plurality of hollow tubes 34 leading from the expansion chamber 32 to the refrigerant return lumen 19 of the catheter body 18 . This embodiment of the heat transfer element 34 can be constructed of a tubular material such as nitinol, which has a temperature dependent shape memory, or some other tubular material having a permanent bias toward a curved shape. The heat transfer element tubes 34 can be essentially straight, originally, at room temperature, but trained to take on the outwardly flexed “basket” shape shown in FIG. 3 at a lower temperature. This allows easier insertion of the catheter assembly 10 through the vascular system of the patient, with the essentially straight but flexible tubes. Then, when the heat transfer element 34 is at the desired location in the feeding artery, such as the internal carotid artery, refrigerant flow is commenced. As the expanding refrigerant cools the heat transfer element 34 down, the heat transfer element takes on the basket shape shown in FIG. 3 . This enhances the heat transfer capacity, while limiting the length of the heat transfer element.
A fourth embodiment of the heat transfer element is shown in FIG. 4 . This embodiment can be constructed of a material such as nitinol. The heat transfer element 36 can be originally shaped as a long loop extending from the distal end of the catheter body 18 , at room temperature, but trained to take on the coiled tubular shape shown in FIG. 4 at a lower temperature, with the heat transfer element 36 coiled around the capillary tube 22 . This allows easier insertion of the catheter assembly 10 through the vascular system of the patient, with the essentially straight but flexible tubular loop shape. Then, when the heat transfer element 36 is at the desired location in the feeding artery, such as the internal carotid artery, refrigerant flow is commenced. As the expanding refrigerant cools the heat transfer element down, the heat transfer element takes on the shape of the coil 36 shown in FIG. 4 . This enhances the heat transfer capacity, while limiting the length of the heat transfer element 36 . FIG. 4 further illustrates that a thermocouple 38 can be incorporated into the catheter body 18 for temperature sensing purposes.
Yet a fifth embodiment of the heat transfer element is shown in FIGS. 5, 6 , and 7 . In this embodiment, an expansion element, such as a capillary tube or orifice, is incorporated within the distal end of the catheter body 18 . This embodiment of the heat transfer element can be constructed of a material such as nitinol. The heat transfer element is originally shaped as a long loop 40 extending from the distal end of the catheter body 18 , at room temperature. The long loop 40 has two sides 42 , 44 , which are substantially straight but flexible at room temperature. The sides 42 , 44 of the long loop 40 can be trained to take on the double helical shape shown in FIG. 6 at a lower temperature, with the two sides 42 , 44 of the heat transfer element 40 coiled around each other. Alternatively, the sides 42 , 44 of the long loop 40 can be trained to take on the looped coil shape shown in FIG. 7 at a lower temperature, with each of the two sides 42 , 44 of the heat transfer element 40 coiled independently. Either of these shapes allows easy insertion of the catheter assembly 10 through the vascular system of the patient, with the essentially straight but flexible tubular loop shape. Then, when the heat transfer element 40 is at the desired location in the feeding artery, such as the internal carotid artery, refrigerant flow is commenced. As the expanding refrigerant cools the heat transfer element down, the heat transfer element 40 takes on the double helical shape shown in FIG. 6 or the looped coil shape shown in FIG. 7 . Both of these configurations enhance the heat transfer capacity, while limiting the length of the heat transfer element 40 .
As shown in FIGS. 8 through 11, the heat transfer element 24 can have external fins 46 , 48 attached thereto, such as by welding or brazing, to promote heat transfer. Use of such fins allows the use of a shorter heat transfer element without reducing the heat transfer surface area, or increases the heat transfer surface area for a given length. In FIGS. 8 and 9, a plurality of longitudinal fins 46 are attached to the heat transfer element 24 . The heat transfer element 24 in such an embodiment can have a diameter of approximately 1.0 millimeter, while each of the fins 46 can have a width of approximately 0.5 millimeter and a thickness of approximately 0.12 millimeter. This will give the heat transfer element an overall diameter of approximately 2.0 millimeters, still allowing the catheter to be inserted into the internal carotid artery.
In FIGS. 10 and 11, a plurality of annular fins 48 are attached to the heat transfer element 24 . The heat transfer element 24 in such an embodiment can have a diameter of approximately 1.0 millimeter, while each of the fins 48 . can have a width of approximately 0.5 millimeter and a thickness of approximately 0.12 millimeter. This will give the heat transfer element an overall diameter of approximately 2.0 millimeters, still allowing the catheter to be inserted into the internal carotid artery.
While the particular invention as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages hereinbefore stated, it is to be understood that this disclosure is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended other than as described in the appended claims.
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A method and apparatus for performing hypothermia of a selected organ without significant effect on surrounding organs or other tissues. A flexible catheter is inserted through the vascular system of a patient to place the distal tip of the catheter in an artery feeding the selected organ. A compressed refrigerant is pumped through the catheter to an expansion element near the distal tip of the catheter, where the refrigerant vaporizes and expands to cool a flexible heat transfer element in the distal tip of the catheter. The heat transfer element cools the blood flowing through the artery, to cool the selected organ, distal to the tip of the catheter.
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FIELD OF THE INVENTION
The invention describes a gas discharge lamp, a reflector, and a lighting assembly.
BACKGROUND OF THE INVENTION
High-intensity discharge lamps (HID lamps) are widely used in automotive headlamp applications, since they can provide an intensely bright light. To ensure traffic safety, characteristics of such lamps such as beam profile, colour temperature, lamp driver characteristics, lamp dimensions, etc., are specified in different countries by the appropriate regulations. For example, in Europe, the beam profile that is to be emitted by a headlamp, i.e. the shape of the low (passing) beam and the shape of the high (driving) beam, is regulated by ECE-R98, where ‘ECE’ stands for ‘Economic Commission for Europe’, while design-specific aspects of discharge light sources for use in such headlamps are regulated by ECE-R99. Often, the lamps specified in these regulations are simply referred to by their designation, e.g. ‘D3S’, ‘D4R’, etc.
An R-type lamp (e.g. a D4R lamp), for use in conjunction with a reflector in a headlamp arrangement, has opaque ‘stripes’ arranged on the outer vessel to block, reflect or absorb some of the light in order to obtain the desired beam shape, for example to prevent glare and to obtain the required cut-off. These stripes generally comprise a ‘vertical’ stripe, i.e. a stripe arranged around the circumference of the lamp near the lamp base, and ‘horizontal’ stripes arranged along the length of the lamp, which is mounted essentially horizontally in a reflector of a lighting assembly, as described in EP 0 708 978 B1. The horizontal stripes in such a prior art lamp are positioned relatively high up on the sides of the lamp in order to achieve a high brightness level below the cut-off and a very low brightness level above the cut-off. At the same time, these effectively block a fraction of the light, which is effectively wasted. Therefore, the overall light output and efficiency for a lamp with such stripes is noticeably lower than for a comparable lamp without stripes. This loss of light is a considerable drawback, since an automotive lamp should deliver as much light as possible into the front beam for visibility and safety reasons. The light absorbed or blocked by the stripes also contributes to an over-heating of the lamp and can result in a shortening of the lifetime of the lamp. The reason for this is that the inner vessel or burner is relatively large, for example in the case of a 35 W D4R lamp, and there is only a small clearance between the burner and the outer vessel. The glass wall of the burner is therefore very close to the glass wall of the outer vessel, and the associated coefficient of thermal conductivity is high. The high temperatures cause an increase in the lamp voltage, and therefore to a reduction in lumen output, as the lamp ages, and can also lead to the development of flicker. The temperature increase is also associated with an unfavourable alteration in the colour of the light output by the lamp. Another unwanted side effect of the high temperatures is the development of cracks in the pinch region of the lamp under the vertical stripe, which can shorten the useful lifetime of the lamp.
Therefore, it is an object of the invention to prolong the lifetime of such a lamp.
SUMMARY OF THE INVENTION
This object is achieved by the gas-discharge lamp according to claim 1 , the reflector according to claim 13 , and the lighting assembly according to claim 15 .
According to the invention, the lamp comprises a vessel, which vessel is partially coated with at least one essentially rectangular longitudinal stripe arranged on the surface of the vessel below a horizontal plane through a longitudinal axis through the centre of the lamp such that, on each side of the lamp, an angle subtended at the lamp centre by the horizontal plane and an upper edge of the longitudinal stripe on that side of the lamp comprises at least 10°, more preferably at least 13°, most preferably at least 15°.
A gas-discharge lamp for an automotive front beam is generally mounted horizontally in an essentially parabolic reflector. An arc-image collected in the right-hand side of the reflector will be reflected upside-down—i.e. inverted—into the left-hand side of the beam profile in front of the vehicle, while an arc-image collected in the left-hand side of the reflector will be reflected upside down into the right-hand side of the beam profile. The orientation of the arc-image in the beam profile corresponds to the angle of the light emitted by the lamp with respect to a horizontal reference plane defined by the lamp's optical axis. With a horizontal lamp mounting position, the longitudinal stripe is also arranged essentially horizontally. Therefore, in the following, the longitudinal stripe may also simply be referred to as a ‘horizontal’ stripe. Furthermore, the terms ‘stripe’ and ‘pinstripe’ may be used interchangeably. The term ‘essentially’, when used in the context of an arrangement, is to be understood to include only negligible deviations from the specified arrangement.
The inventive placement of the horizontal stripe has a number of positive effects.
For instance, the lifetime of the lamp can be favourably prolonged, since the horizontal stripe is located in a ‘cooler’ region of the vessel, i.e. in a region closer to the bottom of the vessel. As a result, the influence of the lower horizontal stripe on the lamp temperature is not as severe, and the temperature in the lamp does not reach the high levels reached in a prior art lamp with a wider horizontal stripe. The lower temperatures are associated with an improvement in light flux and a less pronounced increase in lamp voltage as the lamp ages, since the electrode burn-back is not as pronounced. Furthermore, because the upper edges of the horizontal stripe are positioned at a lower level compared to a prior art lamp, the horizontal stripe therefore blocks less useful light. With the smaller angular region subtended by the upper edges of the longitudinal stripe(s), i.e. the stripes are located lower down on the lamp sides, a higher luminous flux can be obtained for a front beam in the region between 25 m and 60 m in front of the vehicle, while not generating any additional glare. In prior art lamps with horizontal stripes arranged to manipulate the beam profile, light which would be emitted by the lamp in the angular region between about 7.5° and 15° below the horizontal plane is effectively blocked, while causing the temperature in the lamp to increase to an unfavourable level.
The horizontal stripe on the lamp according to the invention may favourably be combined with the circumferential or ‘vertical’ stripe as specified in the currently applicable regulations for automotive headlamps. In this way, the lamp according to the invention can be used in place of a prior art D4R headlamp without having to replace any existing electronics or fittings.
According to the invention, a reflector for a lamp comprises a reflective interior surface realised to deflect light originating from the lamp outward to give a specific beam profile with a bright/dark cut-off line, and wherein the lamp, in particular a lamp according to the invention, is positioned horizontally in the reflector, and wherein the reflective interior surface comprises at least one beam-shaping region realised to deflect a portion or fraction of the light, emitted from the lamp between 0° and at least 10° below a horizontal plane, at a specific region within the beam profile close to the bright/dark cut-off line. Here, the term ‘positioned horizontally in the reflector’ is to be understood to mean that a horizontal longitudinal axis of the lamp essentially coincides with the horizontal optical axis of the reflector. In other words, the horizontal longitudinal axis of the lamp is not tilted with respect to the horizontal optical axis of the reflector.
Also, the reflector according to the invention is preferably realised so that it can be used in place of a prior art reflector in a front beam lighting assembly. With the reflector according to the invention, one of the most relevant parts of a beam profile for an automotive front beam can be optimally illuminated while still satisfying the beam profile conditions laid out in the regulations.
According to the invention, a lighting assembly comprises such a reflector and a lamp, in particular a lamp according to the invention.
The dependent claims and the subsequent description disclose particularly advantageous embodiments and features of the invention.
Preferably, the partial coating can comprise a suitable paint such as an opaque paint applied onto a surface of a vessel of the lamp. The partial coating can be applied in any suitable manner, for example by printing a stripe of a suitable substance onto a vessel of the lamp.
In prior art lighting assemblies, the reflector design was essentially parabolic and symmetrical. However, the desired beam profile for a front beam is asymmetrical, with a ‘shoulder’ in which a portion of the light is projected further into the ‘kerb side’ of the road in order to better illuminate this critical region. Therefore, the prior art arrangement of stripes was designed to form the front beam into the desired asymmetric shape. However, advances in reflector design allow a reflector to perform a certain amount of beam shaping. In a further particularly preferred embodiment of the invention, therefore, the horizontal stripe is arranged essentially symmetrically on the vessel such that the first angle is essentially equal to a second angle subtended at the lamp centre between the horizontal plane and a point on the opposite upper edge of the horizontal stripe. In other words, the upper edges of the horizontal stripe on each side of the lamp are arranged symmetrically about the lamp, i.e. the angle subtended at the lamp centre by the horizontal plane through the lamp centre and the upper edge of the horizontal stripe on one side of the lamp is essentially the same as the angle subtended at the lamp centre by the horizontal plane through the lamp centre and the upper edge of the horizontal stripe on the other side of the lamp. For example, the angles subtended can both comprise 10°, or they can both comprise 15°, etc.
In a further preferred embodiment of the invention, the partial coating comprises a single essentially rectangular stripe, so that the entire underside of the lamp is coated with a single stripe. In this embodiment of the invention, the coldest spot temperature of the bulb is increased, so that the luminance of the lamp is increased accordingly, giving a more favourable beam performance. Furthermore, the colour temperature of the front beam appears more bluish because yellowish stray light generated by the particles of the salt pool is blocked very close to the lamp. In the state of the art the yellowish stray light is blocked by an additional metal shield that surrounds the lower part of the lamp at a distance of more than 10 mm. Part of the yellowish stray light can still escape and tint the beam pattern with unwanted yellowish colour. Also, the homogeneity of the beam, i.e. the light and colour distribution, is improved.
As already mentioned above, a prior art lamp produces a relatively low level of luminous flux owing to the higher placement of the horizontal stripes. Experiments with a lamp with stripes arranged according to the invention have shown that, unexpectedly, the extra light emitted in these regions does not cause glare if the corresponding region of the reflector is designed to reflect the light into the beam profile well within the cut-off line. The larger the angle, the more light can be reflected into an area which is further away from the cut-off line (i.e. closer to the vehicle), thereby increasing the brightness level well bellow the cut-off line. It has been widely accepted that a higher and smooth brightness gradient in the area between 10 m and 60 m in front of the vehicle ensures more relaxed and safer driving. On the other hand, if the subtended angle is significantly greater than 30° below the horizontal, the region of maximum brightness will be shifted mostly within 30 m of the vehicle. Furthermore, particularly for a 35 W lamp, the light originating from the lower regions of the lamp tends to have a yellowish tint owing to the yellowish colour of the stray light originating from the salt pool at the base of the lamp. The resulting beam profile, with the yellowish bright region near the vehicle, can result in the driver focussing his attention on this region and may be hazardous especially at higher velocities. Especially when viewed from in front, the yellowish tint gives the unwanted impression that the headlamp is a halogen headlamp.
In contrast, a 25 W lamp can provide light with a higher colour temperature even for angles in the region of 30° subtended below the horizontal. The reason for this is because of the more even temperature distribution in a 25 W lamp owing to its smaller dimensions, which result in a lower temperature gradient between the hotter upper region of the lamp and the cooler lower region of the lamp. Because of this, the light emitted by a 25 W lamp has significantly less yellowish colouration. Therefore, in a 25 W lamp design, the horizontal stripes can be placed lower down than in a 35 W lamp design.
Since the lamp according to the invention is usually used in a reflector using a baffle as described above to block some of the light emitted in a downward direction, it may not always be strictly necessary to block unwanted light using only the stripes. Therefore, in a further preferred embodiment of the invention, the partial coating comprises a pair of essentially rectangular stripes arranged longitudinally on the surface of the vessel, and the stripes are arranged such that a gap between them is situated above a baffle when the lamp is mounted in such a reflector. The stripes are preferably essentially parallel and arranged at the same height on either side of the lamp and below the horizontal plane. In this way, any light emitted through the gap between the stripes on the lamp underside is still prevented from disturbing the beam profile. At the same time, the light emitted through the gap allows the temperature in the lamp to be maintained at a favourable low level compared to prior art lamps.
To obtain the desired beam shape, the lamp according to the invention preferably also comprises an essentially rectangular stripe arranged circumferentially on a surface of the vessel, wherein a first long side of the stripe is situated close to a base or ballast of the lamp, and the width of the stripe is such that a first angle subtended at a lamp centre between a radius and a point on the first long side of the stripe comprises at most 55°, and a second angle subtended at the lamp centre between the radius and a point on a second long side of the stripe comprises at most 50°.
The narrower vertical stripe has a number of positive effects. For example, because the narrower vertical stripe blocks less light, the influence of the vertical stripe on the lamp temperature is not as severe, and the temperature in the lamp does not reach the high levels reached in a prior art lamp with a wider vertical stripe. As already indicated above, the lower temperatures are associated with an improvement in light flux and a less pronounced increase in lamp voltage as the lamp ages. These advantages can be obtained by the simple and economical reduction in the width of the vertical stripe, making use of the fact that the light emitted from ‘behind’ this vertical stripe would not in any case make any valuable contribution to the beam profile. The reason for this is because the light emitted towards the rear of an enclosing reflector is generally not deflected into the beam, for reasons that will be explained below. This ‘superfluous’ light, which was unnecessarily blocked in a prior art lamp with a wide vertical stripe, can therefore be safely allowed to exit the lamp in that region between the vertical stripe and the lamp base without detracting from the beam profile.
Usually, a reflector for a front lighting assembly comprises a cut-out area close to the base of the lamp, to allow the lamp base to be connected to the reflector. For example, this location can be part of the lamp base, a flange of the reflector, or even an opening in the back of the reflector. This fact is put to use by the lamp with the vertical stripe according to the invention, since this part of the reflector is therefore generally not used for collecting or deflecting light into the front beam. Any light emitted ‘behind’ the vertical stripe arrives at this part of the reflector or escapes through an opening in the reflector. Since the light would not be deflected into the beam anyway, there is no need to block it, and the vertical stripe can be made narrower as a result.
In one embodiment of the invention, the vertical stripe entirely surrounds the vessel, i.e. the length of the vertical stripe is essentially equal to the circumference of the vessel so that the vertical stripe is arranged around the entire circumference in a continuous manner.
In order to obtain the beam profile set out in the regulations, a lighting assembly with such a lamp in a reflector generally also comprises a baffle located underneath the lamp to block any light emitted downwards from the lamp. With such a baffle in place, the front beam essentially comprises only light deflected from the upper regions of the reflector. Alternatively, therefore, in another embodiment of the invention, the length of the circumferential or vertical stripe can be shorter than the circumference of the vessel, so that the gap between the ends of the stripe faces ‘downwards’ towards the baffle.
The lamp according to the invention, with the inventive arrangement of a horizontal stripe and, optionally, a vertical stripe can be realised for various rated power values. For example, by appropriate choice of dimensions, the lamp could be realised as a 35 W D4R lamp. To satisfy regulations, such a lamp could have a (wider) vertical stripe arranged in the prior art manner, while using the inventive horizontal stripe arrangement to improve the beam quality and to prolong the lamp lifetime.
For an optimal light output as well as an advantageously long lifetime, the lamp is preferably realised for a nominal power of 25 W. In a particularly preferred embodiment of a 25 W lamp according to the invention, the lamp comprises an inner discharge vessel enclosed in an outer vessel, whereby the capacity of the inner discharge vessel or burner is between 15 μl and 23 μl, the inner diameter of the inner discharge vessel is between 2.0 mm and 2.4 mm; and the outer diameter of the inner discharge vessel is between 5.2 mm and 5.8 mm.
The stripes could be applied to the inner vessel and/or the outer vessel. For example, a vertical stripe can be applied to the inner vessel, and the outer vessel can have the horizontal stripes. Equally, both vessels can be coated with a partial stripe, so that, in combination, the effect is the same as if only the outer vessel were coated with the stripes. However, since the inner vessel is hottest, any stripe applied to the inner vessel may contribute to an unwanted temperature increase. Furthermore, since the inner vessel is very small and quite bulbous, it may be impracticable to apply a precise stripe. Therefore, in a preferred embodiment of the invention, the partial coating is arranged on an outer surface of the outer vessel, since the outer vessel is essentially a regular cylinder, at least in those regions to which the stripe(s) would be applied.
As explained above, the partial coating can be applied as a pair of essentially rectangular horizontal parallel stripes, one on either side of the lamp, preferably on the outer vessel. For such a realisation of the lamp according to the invention, the width of a longitudinal stripe comprises at most 1.9 mm, more preferably at most 1.7 mm, and most preferably at most 1.5 mm. With such a favourable arrangement of narrow horizontal stripes, the light flux can be increased considerably as already described above. An up to 4% increase in light flux—i.e. about 80 lumen—was observed in measurements taken for a lamp according to the invention. The additional light is emitted in regions that can be very efficiently utilised to illuminate the bright/dark cut-off boundary, thus improving the range of the beam profile. An up to 3% increase in light flux was observed for the inventive lamp with the narrower horizontal stripes after 1500 hours of burning. At the same time, since the area covered by the partial coating is considerably reduced compared to prior art lamps, the temperature of the lamp can be maintained at a favourably lower level, so that chemical reactions in the burner, in which electronegative species such as free iodine are created, will be reduced, so that the increase in lamp voltage is less. In experiments with the lamp according to the invention and comparable prior art lamps, the increase in lamp voltage was observed to be up to 5 V less.
In the prior art lamps, as already mentioned above, the vertical stripe is unfavourably wide, up to 8.3 mm. Not only does this wide stripe unnecessarily block light that would not be included in the beam anyway, the wide stripe also contributes to an increase in lamp temperature. Therefore, in a preferred embodiment of the invention, the width of the circumferential stripe preferably comprises at most 4.5 mm, more preferably at most 4.0 mm, and most preferably at most 3.5 mm. For a 25 W lamp with the above dimensions, the width of the vertical stripe applied to the outside vessel can be as little as 3.5 mm, which is much narrower than the vertical stripe on any comparable prior art lamp, while still ensuring that the relevant regulation is satisfied.
Experiments with a 25 W lamp according to the invention have shown a light output that was surprisingly greater than expected. An explanation for the unexpected increase in light output for the 25 W lamp may be given by its different three-dimensional light intensity distribution owing to the geometry of the lamp vessels and the temperature conditions in the lamp. In the state of the art, the stripes are positioned significantly higher so that the temperature at the bottom of the vessel is lower compared to the situation claimed in this application. In case of a higher cold spot temperature (at the lower part of the vessel) the width of the arc is increased, resulting in higher light intensities particularly in the region of the upper edge of the horizontal pinstripe. Also, the burner of a 25 W lamp has a smaller inner and outer diameter and a smaller electrode distance. This geometry results in a lower temperature gradient between the top and the bottom regions of the burner. Thus the ratio of light radiated out towards the side of the lamp to light radiated towards the top of the lamp is significantly higher for the 25 W lamp. Also, the colour temperature of the light radiated in the direction of the edge of the inventive horizontal pinstripe is significantly higher due to the reduced temperature differences between the upper and lower vessel regions. Even for a 25 W lamp with horizontal pinstripes applied according to the R99 regulations, an increase of about 4% in light output was achieved compared to a comparable 35 W lamp. For the inventive lower placement of the horizontal stripes, the light output was increased by a very favourable 10%.
In addition to the advantages with respect to bulb physics (lamp lifetime, flicker, lamp voltage) the lower placement of the longitudinal pinstripe and the narrower pinstripe width results in a significantly higher beam flux and a significantly higher performance due to the use of additional arc images. These images can be very efficiently used—mainly by the horizontal reflector regions—and can contribute to a longer as well as a wider beam. In this way, the visibility is considerably improved for the driver of the vehicle, while any oncoming vehicles are not subject to an increased level of glare, since the additional arc images are projected below the cut-off line. The beam flux of current reflection-type headlamps can be increased by up to 10%.
The inventive pinstripe arrangement can be favourably used in conjunction with a symmetric baffle and an asymmetric or free-shape reflector, following the technology evolution from asymmetric H4 baffle design to symmetric DFCS baffle design. When a free-shape reflector design is used, neither an asymmetric baffle nor an asymmetric arrangement of horizontal pinstripes is required.
In a preferred embodiment of the invention, the reflector comprises at least one first beam-shaping region on one side of the lamp for deflecting a light portion into a region close to a cut-off boundary of a horizontal region of the beam profile, and at least one second beam-shaping region on the other side of the lamp for deflecting a light portion close to a cut-off boundary of a shoulder region of the beam profile.
In another preferred embodiment of the invention, the reflector comprises an asymmetric arrangement of beam-shaping regions for forming an asymmetric beam profile with light collected from an essentially symmetrical light source. A reflector with such an asymmetric geometry or surface topology can then optimally be used with a lamp having a symmetrical arrangement of horizontal stripes, while still producing an asymmetric front beam as required by the regulations.
Other objects and features of the present invention will become apparent from the following detailed descriptions considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic representation of a prior art gas-discharge lamp;
FIG. 2 shows a schematic representation of a gas-discharge lamp according to a first embodiment of the invention;
FIG. 3 shows a schematic representation of a gas-discharge lamp according to a second embodiment of the invention;
FIG. 4 shows a lighting assembly according to an embodiment of the invention;
FIG. 5 shows a cross section through a lighting assembly according to the invention and a corresponding beam profile;
FIG. 6 shows a schematic representation of a reflector according to the invention;
FIG. 7 shows a bar chart of initial lumen output;
FIG. 8 shows graphs of lumen maintenance;
FIG. 9 shows graphs of lamp voltage.
In the drawings, like numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 shows a cross section of a prior art gas-discharge lamp 10 , with a partial coating 11 , 12 comprising a circumferentially arranged stripe 11 and a pair of longitudinally arranged stripes 12 , 13 . The lamp 10 shown corresponds to a D4R lamp, with a ballast 6 or base 6 , for use in an automotive headlight assembly. The width of the circumferential stripe 11 is defined in the appropriate regulation, in this case ECE R99, by the angles α 1 , α 2 subtended at the lamp centre between a radius r and points on the outer edges of the circumferential stripe 11 . The regulation ECE R99 requires that the smaller angle α 1 be 45°±5°, and that the larger angle α 2 be at least 70°. On a D4R lamp, such a circumferential stripe 11 can therefore have a width of about 8.3 mm, and usually covers a substantial part of the underlying pinch region. A pair of longitudinal stripes 12 , 13 is arranged one of each side of the lamp 10 . This is illustrated in the cross-section A-A′ shown on the left of the diagram. According to the regulation ECE R99, these longitudinal stripes 12 , 13 are arranged asymmetrically on the lamp outer vessel 5 such that one stripe 13 is lower than the other stripe 12 . The ‘higher’ stripe 12 is positioned to lie just below the horizontal plane P, while the upper edge of the lower stripe 13 is positioned at most 15° below the horizontal plane P. The reason for this arrangement is the older reflector designs, which required an asymmetric light source in order to produce the required asymmetric front beam. However, this known prior art arrangement of stripes 11 , 12 , 13 leads to the problems mentioned above, namely a shorter lamp lifespan (owing to the excessive heat that develops in the pinch region under the circumferential stripe 11 ), an uneven light intensity distribution in the beam profile (owing to the pronounced temperature gradient between the upper and lower regions of the lamp 1 ), and a lower light output (owing to the light lost in the areas blocked by the longitudinal stripes 12 , 13 ).
FIG. 2 shows a gas-discharge lamp 1 according to a first embodiment of the invention. The construction of the lamp 1 is essentially the same as in the above FIG. 1 , in order to comply with regulations regarding lamp size, ballast, etc. The relative sizes of the inner and outer vessels 4 , 5 will depend on whether the lamp is realised as a 25 W lamp or a 35 W lamp. In this embodiment, two horizontal stripes S H are arranged symmetrically on the outer vessel 5 . In contrast to the horizontal stripes 12 , 13 of FIG. 1 , the horizontal stripes S H are arranged symmetrically on either side of the lamp 1 , are positioned lower down, and are narrower than the prior art stripes 12 , 13 . This is illustrated in the cross-section A-A′ shown on the left of the diagram. In this embodiment, the longitudinal stripes S H are arranged symmetrically on the lamp outer vessel 5 such that an angle β H1 , β H2 subtended at the lamp centre between the horizontal plane P and a point on an upper edge 16 , 17 of a longitudinal stripe S H comprises 15°. The angular region γ H between the upper edges 16 , 17 of the horizontal stripes S H and below the horizontal plane P comprises only 150°. As a result, the light output of the lamp 1 is increased, since less light is blocked by the lower and narrower longitudinal stripes S H , and more ‘useful’ arc images can be collected by a surrounding reflector and used to form a brighter front beam, as will be shown below.
The diagram also shows a rectangular vertical stripe S V arranged about the circumference of the outer vessel 5 of the lamp 1 , such that the short ends of the vertical stripe S V do not meet on the underside of the lamp 1 . The width w V of the vertical stripe S V is defined by the angles α V1 , α V2 subtended between a radius r through the lamp centre and points on the outer edges 14 , 15 of the circumferential stripe S V . In this embodiment of the invention, the smaller angle α V1 to the inner edge 15 closer to the burner 4 is about 50°, and the larger angle α V2 to the outer edge 14 closer to the base 6 is only about 55°. Therefore, the vertical stripe S V has a width w V of about 3.5 mm, so that it only covers a small section of the underlying pinch region. During operation of the lamp, then, ‘superfluous’ light L S (light that would not be used in any case to contribute to the front beam) can leave the lamp 1 without being absorbed or reflected back into the lamp 1 , and therefore the temperature in the lamp is not unnecessarily increased.
FIG. 3 shows a further embodiment of a lamp 1 according to the invention. Here, a vertical stripe S V ′ and a horizontal stripe S H ′ are arranged as shown on the outer surface of the outer vessel 5 . In this realisation, the vertical stripe S V ′ extends all the way around the outer vessel 5 , and the horizontal stripe S H ′ comprises a single stripe S H ′. The position and width of the vertical stripe S V ′ can be the same as in FIG. 2 above. In this embodiment, the defining angle β H1 , β H2 of the horizontal stripe S H ′ can be smaller, for example 10°, as shown in the cross-section A-A′ on the left of the diagram. In this case, the angular region γ H between the upper edges 16 , 17 of the horizontal stripes S H comprises 160°.
In prior art lamps, the stripes were required to provide an asymmetric light source, and the prior art reflectors were largely symmetrical. The lamp 1 according to the invention makes use of the fact that the reflectors available at present can be favourably designed to form light—even light originating from a symmetrical light source—into an asymmetric front beam. Since the reflector can achieve the required asymmetry largely on its own, the width and placement of the stripes can be favourably adjusted as described above to optimise the light output and to prolong the lamp lifetime.
FIG. 4 shows a lighting assembly 9 with a lamp 1 according to the invention and a reflector 8 . As can be seen clearly in the diagram, the circumferential stripe S V ′ is narrow, so that light L S , which is in any case superfluous, can pass through the outer vessel 5 into the base region of the lamp 1 . This light can, for example, be absorbed in the rear of the reflector 8 or can pass through an opening 83 in the rear of the reflector 8 . ‘Wasting’ the superfluous light L S in this way does not detract from the beam quality. Instead, the lamp 1 is protected from overheating by the narrow width of the vertical stripe S V ′.
FIG. 5 illustrates the beneficial effect of the inventive arrangement of horizontal stripes S H on a lamp 1 in a reflector 8 for an automotive headlamp arrangement. On the right-hand side of the diagram, a cross-section through the lamp 1 and reflector 8 is shown, and regions 80 A, 80 B, 81 A, 81 B are indicated on the inside surface of the reflector 8 . Images 20 A, 20 B, 21 A, 21 B of the discharge arc 2 originating from light L 20A , L 20B , L 21A , L 21B collected at these regions 80 A, 80 B, 81 A, 81 B, are projected onto the beam profile 3 according to the relevant regulation, for example R98, as shown in the left-hand side of the diagram. Images 20 A, 20 B (dotted lines) show the region close to the cut-off 31 and in the shoulder 32 that can be illuminated with a prior art lamp having higher horizontal stripes. Because these arc images 20 A, 20 B are collected relatively high up in the reflector 8 , near to or above the horizontal plane P, they are not tilted to any significant extent, and lie more or less along the cut-off line of the beam profile 3 . The additional images 21 A, 21 B (solid lines) that are projected into the beam profile 3 ensure a better illumination by the front beam owing to the greater light flux and the longer reach of the front beam. These additional images 21 A, 21 B are collected on account of the inventive lower arrangement of longitudinal stripes S H on the outer vessel 5 . Because these images 21 A, 21 B are collected lower down in the reflector 8 , they are tilted noticeably compared to the other arc images 20 A, 20 B, and make a favourable contribution to the overall brightness of the beam profile.
FIG. 6 shows a view of a reflector 8 according to the invention. Here, a lamp 1 with a stripe arrangement S V , S V ′, S H , S H ′ according to the invention is mounted horizontally in the reflector. Images of the discharge arc 2 , collected in the interior of the reflector 8 , are deflected outward to give a beam profile 3 with a desired cut-off line 31 and a ‘shoulder’ 32 relative to axes H, V. The diagram shows the regions 81 A, 81 B for collecting additional light L 21A , L 21B allowed by the lower placement of horizontal stripes S H , S H ′ . This additional light is deflected onto the beam profile as the arc images 21 A, 21 B. The positions and orientations of these additional arc images 21 A, 21 B in the diagram is exemplary. The position of the horizontal stripe(s) S H , S H ′ and the actual realisation of the reflector regions 81 A, 81 B will influence the orientation and positioning of the arc images 21 A, 21 B. For example, a lower placement of the horizontal stripe(s) S H , S H ′ will result in a more tilted arc image 21 A, 21 B. Using this reflector 8 with the inventive lamp 1 allows a better illumination of the region in front of the vehicle between 25 m and 60 m owing to the improved reach of the beam and to the better illumination in the cut-off 31 and shoulder 32 regions of the beam profile 3 .
FIGS. 7-9 show experimental results obtained for 35 W and 25 W D4R lamp batches A 35 , A 25 according to the invention, for D4R 35 W and 25 W lamp batches B 35 , B 25 with a prior art pinstripe arrangements, and for D4R 35 W and 25 W lamp batches C 35 , C 25 with no pinstripes.
FIG. 7 shows a bar chart of initial lumen output in percent (%) for different batches of automotive gas-discharge lamps measured 15 hours after burning in. Batch B 35 comprised prior art 35 W lamps with pinstripes arranged according to the R99 regulation, while batch B 25 comprised prior art 25 W lamps with such pinstripes.
Batches C 35 , C 25 comprised 35 W and 25 W D4R lamps respectively, without any stripes. To satisfy the regulation, an automotive lamp 25 W or 35 W lamp must deliver 3200±450 lumens at 15 hours after burning in. The light output that can be achieved initially is given as 100%. Batch A 35 comprised 35 W lamps and batch A 25 comprised 25 W lamps, in each case with horizontal stripes arranged according to the invention, i.e. lower down and narrower, and a narrow vertical stripe. For these batches, improvements in light output of 5% and 3% respectively were obtained. Evidently, since the absence of any stripes means no light is blocked, the light output for batches C 35 , C 25 are highest, and these are only given as a reference against which the favourable improvements of batches A 35 and A 25 can be compared. As the chart shows, the lamp according to the invention, while having stripes to assist in obtaining a desired beam shape, can still provide an initial lumen output favourably close to that of a lamp without any stripes.
FIG. 8 shows graphs of lumen maintenance measured for the lamp type batches A 25 , B 25 , C 25 of FIG. 1 after 1500 hours of burning. An initial value of 100% corresponds to the lumen output of each lamp batch type after burning in. Lamp type batch B 25 showed relatively poor lumen maintenance, dropping to only about 89% of its initial value after 1500 hours. Batch A 25 showed quite favourable lumen maintenance, dropping only to about 92%. The lamp batch C 25 , without any partial coating, dropped to about 95%, so that the lumen maintenance of lamp type batch A 25 compares quite well to a lamp type without any stripes. In the 25 W lamp, the burner is small, but the outer vessel is of the same size as for a 35 W lamp. Therefore, the clearance between burner and outer vessel is greater, and the coefficient of thermal conductivity is lower. The burner is therefore to some extent thermally insulated from the outer vessel, so that heat generated because of the stripe regions does not affect the temperature in the burner to the same extent as in a prior art 35 W lamps. This explains the very favourable lumen maintenance of the 25 W lamps according to the invention. Measurements taken for the lamp batches A 35 , B 35 , C 35 showed a drop in lumen maintenance to 82%, 72% and 87% respectively after 2000 hours of burning, so that the 35 W lamp A 35 with the inventive pinstripe arrangement exhibited a favourable lumen maintenance compared to a prior art lamp B 35 with pinstripes.
FIG. 9 shows graphs of lamp voltage measured for batches A 25 , B 25 , C 25 of FIG. 7 and FIG. 8 after 1500 hours of burning. An initial value of 100% corresponds to the lamp voltage of each lamp batch type after burning in. Lamp batch B 25 showed a marked increase in lamp voltage after 1500 hours, rising to about 114%. The lamp voltage of lamp batch C 25 , without any stripes, increased to about 113%. Lamp batch A 25 showed a very favourably low increase in lamp voltage, which rose to only about 109%. Positive effects of the low increase in lamp voltage are a reduced tendency to flicker and a prolonged lamp lifetime. Owing to the better thermal insulation of the inner vessel, the temperature in the 25 W lamp according to the invention can be maintained at a favourably low level, which explains the slower increase in lamp voltage even compared to a 35 W lamp with inventive stripe arrangement. Measurements taken for the lamp batches A 35 , B 35 , C 35 showed an increase in lamp voltage of 127%, 131% and 135% respectively after 2000 hours of burning, so that the 35 W lamp with the inventive pinstripe arrangement exhibited the lowest percent increase in lamp voltage over lamp lifetime.
Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention. For the sake of clarity, it is also to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements.
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The invention describes a gas-discharge lamp ( 1 ) comprising a vessel ( 5 ), which vessel ( 5 ) is partially coated with at least one longitudinal stripe (S H , S H ′) arranged on the surface of the vessel ( 5 ) below a horizontal plane (P) through a longitudinal axis (X) through the centre of the lamp ( 1 ) such that, on each side of the lamp, an angle (β H1 , β H2 ) subtended at the lamp centre by the horizontal plane (P) and an upper edge ( 16, 17 ) of the longitudinal stripe (S H , S H ′) on that side of the lamp comprises at least 10°, more preferably at least 13°, most preferably at least 15°. The invention also describes a reflector ( 8 ) for a lamp ( 1 ), comprising a reflective interior surface realized to deflect light (L 20A , L 20B , L 21A , L 21B ) originating from the lamp ( 1 ) outward to give a specific beam profile ( 3 ) with a bright/dark cut-off line ( 31 ) and a shoulder ( 32 ), and wherein the lamp ( 1 ), in particular a lamp ( 1 ) according to any of claims 1 to 12 , is positioned horizontally in the reflector ( 8 ), and wherein the reflective interior surface comprises at least one beam-shaping region ( 81 A, 81 B) realised to deflect a portion (L 21A , L 21B ) of the light (L 20A , L 20B , L 21A , L 21B ), emitted from the lamp ( 1 ) between 7.5° and 15° below a horizontal plane (P), at a specific region ( 21 A, 21 B) within the beam profile ( 3 ). The invention further describes a lighting assembly ( 9 ) comprising such a reflector ( 8 ) and a lamp ( 1 ), in particular a lamp ( 1 ) according to the invention.
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